Pi̇pe Works

CONTENTS
STEEL PIPES.........................................................................................................................20
1 SUBJECT AND SCOPE....................................................................................................20
2 STEEL MATERIAL CHARACTERISTICS..................................................................20
2.1 Materials...........................................................................................................................20
2.2 Chemical Composition.....................................................................................................20
2.3 Mechanical Characteristics.............................................................................................20
3 PIPE MANUFACTURING...............................................................................................21
3.1 Manufacturing..................................................................................................................21
3.2 Weld Seam........................................................................................................................22

3.2.1 Post Weld Process........................................................................................................22
3.3 Dimensions and Dimension Tolerances.........................................................................22

3.3.1 Dimensions..................................................................................................................22
3.3.2 Pipe lengths..................................................................................................................22
3.3.3 Tolerances....................................................................................................................23
3.3.4 Outside Diameter and Tolerances................................................................................23
3.3.5 Wall Thickness and Tolerances...................................................................................23
3.3.6 Weld Seam Height Tolerance......................................................................................23
3.3.7 Pipe End Tolerances....................................................................................................23
3.3.8 Tolerance Class and Certification................................................................................24
3.4 Weights..............................................................................................................................24
3.5 Pipe Straightness..............................................................................................................25
3.6 Ovality...............................................................................................................................25
3.7 Surfaces.............................................................................................................................25
3.8 Marking of Pipes and Special Parts...............................................................................25
4 ISOLATION OF STEEL PIPES......................................................................................26
4.1 Cleaning of Pipe Surfaces................................................................................................26
4.2 Isolation of Pipe External Surfaces................................................................................26

4.2.1 External Coating..........................................................................................................26
4.2.1.1 Epoxy Coating......................................................................................................26
4.2.1.2 Copolymer Layer Application..............................................................................26
1
4.2.2 Polyethylene Coating...................................................................................................27
4.2.2.1 Polyethylene Coating Thickness...........................................................................27
4.2.3 Bitumen-based Isolation..............................................................................................27
4.3 Internal Isolation of Steel Pipes......................................................................................28

4.3.1 Internal Isolation of Small Diameter Pipes..................................................................28
4.3.2 Internal Coating of Pipes.............................................................................................28
4.3.3.2 Coating of Pipe Internal Surfaces Using Concrete with Special Additive...........28
4.3.3.2.1 Scope..............................................................................................................28
4.3.3.2.2 Description.....................................................................................................28
4.3.3.2.3 Application Method and Necessary Equipment............................................29
4.3.3.2.4 Concrete Coating Adherence and Strength Characteristics...........................29
4.3.3.2.5 Coating Surface Smoothness and Layer Thickness.......................................30
4.3.3.2.6 Pipe Ends.......................................................................................................30
4.3.3.2.7 Concrete Coating Adherence and Strength Characteristics...........................30
4.3.3.2.8 Proof of Quality.............................................................................................30
4.3.3.2.9 Internal Isolation of Drinking water Pipes.....................................................31
5 SAMPLING, INSPECTION AND TESTS......................................................................31
5.1 Sampling...........................................................................................................................31
5.1.1 Separation of Samples..................................................................................................31
5.1.2 Material Tests...............................................................................................................32
5.1.3 Pipe Material Characteristics and Material Tests........................................................32
5.1.3.1 Steel and Steel Characteristics..............................................................................32
5.2 External Coating Inspection and Tests..........................................................................33

5.2.1 Visual Inspection.........................................................................................................33
5.2.2 Control of Coating Adherence to Pipe.........................................................................33
5.2.3 Control of Coating Defects..........................................................................................33
5.2.4 Other Tests...................................................................................................................33
5.2.5 General Provisions Regarding External Coating Tests................................................33
5.2.6 Sampling and Tests During Delivery of Pipes.............................................................33
5.2.7 Inspection and Tests Reports.......................................................................................34
5.3 Characteristics of Manufactured Pipe...........................................................................35
5.4 Waterproofing..................................................................................................................35
5.5 Pipe Delivery and Quality Warranty.............................................................................35
6 GENERAL DELIVERY CONDITIONS FOR PIPES...................................................35
6.1 Delivery.............................................................................................................................35
6.2 Place of Delivery:.............................................................................................................35
6.3 Transport and Storage of Pipes......................................................................................35

6.3.1 Loading and Unloading of Pipes..................................................................................35
6.3.2 Storage of pipes............................................................................................................36
7 GENERAL CHARACTERISTICS..................................................................................37
2
8 DIMENSIONS AND QUANTITY OF STEEL PIPES TO BE SUPPLIED.................38
9 INSPECTION.....................................................................................................................38
9.1 Visual inspection..............................................................................................................38
9.2 Dimensional Inspection...................................................................................................38
9.3 Pipe Isolation Test............................................................................................................38
9.4 Production Tests...............................................................................................................38
9.5 Factory Made Bends........................................................................................................39
9.6 Tees and Y’s....................................................................................................................39
9.7 Steel Pipes with Rubber Gasket Spigots........................................................................39

9.7.1 Manufacturing of Steel Pipes with Rubber Gasket Spigots.........................................39
9.7.2 Joints of Steel Pipes with Rubber Gasket Spigot.........................................................40
9.8 Coating of Weld Seams....................................................................................................40
10 MARKING.......................................................................................................................40
11 PACKAGING...................................................................................................................40
12 CONTENT OF OFFER...................................................................................................41
13 ACCEPTANCE - CONDITIONAL ACCEPTANCE - REJECTION........................41
13.1 Acceptance......................................................................................................................41
13.2 Conditional Acceptance.................................................................................................41
13.3 Rejection.........................................................................................................................42
14 DELIVERY......................................................................................................................42
15 ORDER FORM................................................................................................................42
16 TECHNICAL INSPECTION.........................................................................................42
17 TRANSPORT AND STORAGE.....................................................................................42
HDPE 100 (HIGH DENSITY POLYETHYLEN) PIPES..................................................43
2 GENERAL....................................................................................................................43
3
2.2 Pipe Characteristics.........................................................................................................43
2.2.1 Physical Characteristics.............................................................................................43
2.2.2 Chemical Characteristics...........................................................................................44
2.3 Standards..........................................................................................................................44
2.4 Raw Materials..................................................................................................................44
2.5 Technical Characteristics................................................................................................45
2.6 Pipe Jointing Methods.....................................................................................................46
2.7 Wear Resistance...............................................................................................................46
2.8 Nominal Pressure.............................................................................................................46
2.9 Special Conditions............................................................................................................47
3 INSPECTION AND TESTS..............................................................................................47
4 DIMENSIONS AND TOLERANCES..............................................................................47
5 JOINTING..........................................................................................................................47
6 LAYING DESIGN.............................................................................................................48
7 MARKING.........................................................................................................................48
8 TRANSPORT AND STORAGE OF PIPES....................................................................48
8.1 Loading and unloading of pipes......................................................................................48
8.2 Storage of pipes................................................................................................................49
9 GENERAL CHARACTERISTICS..................................................................................49
10 DIMENSIONS AND QUANTITY OF STEEL PIPES TO BE SUPPLIED...............50
11 GENERAL DELIVERY CONDITIONS FOR PIPES.................................................50
11.1 Delivery...........................................................................................................................50
GLASS REINFORCED PLASTIC (GRP) PIPES...............................................................51
1 GENERAL..........................................................................................................................51
2 DEFINITIONS...................................................................................................................51
2.1 Glazing gasket..................................................................................................................51
4
2.2 Trimmed Glass Fiber.......................................................................................................51
2.3 Glass Texture....................................................................................................................51
2.4 Surface Tulle.....................................................................................................................52
2.5 Coating Layer...................................................................................................................52
2.6 Resin.............................................................................................................................52
2.7 Glass Felt...........................................................................................................................52
2.8 Aggregate..........................................................................................................................52
2.9 Nominal Pressure.............................................................................................................52
2.10 Nominal Rigidness.........................................................................................................52
3 CONNECTION TYPES....................................................................................................53
3.1 Sleeve Joint.......................................................................................................................53
3.2 Gasket Spigot Joint..........................................................................................................53
3.3 Hand lay-up connection...................................................................................................53
3.4 Flanged Joint....................................................................................................................53
4 CLASSIFICATION...........................................................................................................53
4.1 Classification by Pressure Classes..................................................................................53
4.2 Classification by Rigidness Classes................................................................................54
5 MANUFACTURING.........................................................................................................54
5.1 Fiber Wrapping Method.................................................................................................54

5.1.1 Internal Surface Layer..................................................................................................54
5.1.2 Strength Layers............................................................................................................54
5.1.3 External Surface Layer................................................................................................55
5.2 Centrifugal Casting Method...........................................................................................55

5.2.1 External Surface Layer................................................................................................55
5.2.2 Strength Layers............................................................................................................55
5.2.3 Barrier Layer................................................................................................................55
5.2.4 Primer layer..................................................................................................................55
6 TECHNICAL SPECIFICATIONS..................................................................................55
6.1 Length...............................................................................................................................55
6.2 Surface Quality.................................................................................................................55
5
6.3 Nominal Diameters..........................................................................................................56
6.4 Wall Thickness.................................................................................................................56
6.5 Flatness of Pipe Ends.......................................................................................................56
6.6 Impermeability.................................................................................................................56
6.7 Nominal Diameters..........................................................................................................56
6.8 Inside diameter.................................................................................................................56
7 INSPECTION AND ACCEPTANCE CRITERIA.........................................................57
7.1 Impermeability Test.........................................................................................................57
7.2 Circular Tensile Strength Test.......................................................................................58
7.3 Longitudinal Tensile Strength Test................................................................................58
7.4 Rigidness Tests.................................................................................................................58
7.5 Factory Product Control Tests........................................................................................58
8 GENERAL DELIVERY CONDITIONS FOR GRP PIPES..........................................59
8.1 Marking of Pipes and Special Parts...............................................................................59
8.2 Surface Appearance of GRP Pipes.................................................................................59
9 DESIGNING OF GRP PIPES AND SPECIAL PARTS................................................59
9.1 Hydraulic..........................................................................................................................59
9.2 Rigidness Class.................................................................................................................60
10 WATER SUPPLY PIPELINE EQUIPMENT..............................................................62
10.1 Fittings............................................................................................................................62
10.2 Entrance into Pipelines (Manholes).............................................................................62
10.3 Manhole Covers.............................................................................................................62
11 PIPELINE CONSTRUCTION.......................................................................................62
11.1 General............................................................................................................................62
11.2 Application......................................................................................................................63
11.3 Excavation Works..........................................................................................................63
11.4 Trench Filling.................................................................................................................63

6
11.5 Loading, Unloading and Storage of GRP Pipes...........................................................64
11.6 Laying Method of GRP Pipes.......................................................................................64

11.6.1 Control of Pipes before Laying..................................................................................64
11.6.2 Lowering of Pipes into Trench..................................................................................64
11.6.4 Rigid Connections and Fixing Blocks of GRP Pipes.................................................65
11.6.5 Hydrostatic and Impermeability Tests of GRP Pipeline............................................66
ASBESTOS CEMENT PIPE.................................................................................................67
1 GENERAL..........................................................................................................................67
1.2 Characteristics and Manufacturing...............................................................................68
2.1 Sampling, Pressure and Impermeability Test...............................................................71
2.2 Test Costs..........................................................................................................................71
3 MARKING.........................................................................................................................72
4 PACKAGING.....................................................................................................................72
5 CONTENT OF OFFER.....................................................................................................72
6 ACCEPTANCE - CONDITIONAL ACCEPTANCE - REJECTION..........................72
6.1 Acceptance........................................................................................................................72
6.2 Conditional Acceptance...................................................................................................73
6.3 Rejection...........................................................................................................................73
7 DELIVERY........................................................................................................................73
8 ORDER FORM..................................................................................................................73
9 TECHNICAL INSPECTION...........................................................................................73
DUCTILE PIPES....................................................................................................................75
1.1 Norms and Standards......................................................................................................75
1.2 Materials...........................................................................................................................75
7
2 TECHNICAL CHARACTERISTICS.............................................................................75
2.1 General..............................................................................................................................75
2.2 Molds.................................................................................................................................76
2.3 Working Pressure............................................................................................................76
2.4 Dimensions........................................................................................................................76
2.5 Thickness of Ductile Pipes and Fittings.........................................................................76
2.6 Quality of Ductile Pipe, Fitting and Other Pipes...........................................................77
2.7 Thickness and Mass Tolerances.....................................................................................77
2.8 Maximum Working Pressure And Internal Pressure Test..........................................77
3 COATINGS........................................................................................................................77
3.1 Internal Coatings.............................................................................................................77
3.2 External Coatings.............................................................................................................78
4 HEAD CONNECTIONS...................................................................................................79
4.1 Pipes with Socket and Spigot..........................................................................................79
4.2 Flanged Pipes....................................................................................................................79
4.3 Fittings and Connecting elements...................................................................................80
5 GASKETS...........................................................................................................................81
6 BOLTS AND NUTS...........................................................................................................81
7 TOLERANCES..................................................................................................................81
7.1 Thickness Tolerances.......................................................................................................81
7.2 Manufacturing Lengths and Length Tolerances..........................................................81
7.3 Mass Tolerances...............................................................................................................82
7.4 Coating Tolerances..........................................................................................................82
8 SAMPLING AND TESTS.................................................................................................82
8.1 Sampling...........................................................................................................................82
8.2 Manufacturing Tests........................................................................................................82
8.3 Tests and Inspections at the Time of Entrance into the Employer’s Warehouse......83
8
8.3.1 Physical Inspection......................................................................................................83
8.3.2 Chemical Inspections...................................................................................................83
8.3.3 Metallographic Inspections..........................................................................................83
8.3.4 Mechanical Inspections................................................................................................83
8.4 Coating Tests....................................................................................................................84
8.5 Test Costs..........................................................................................................................84
9 MARKING.........................................................................................................................84
10 PACKAGING...................................................................................................................85
11 CONTENT OF OFFER...................................................................................................85
12 ACCEPTANCE- CONDITIONAL ACCEPTANCE - REJECTON..........................86
12.1 Acceptance......................................................................................................................86
12.3 Rejection.........................................................................................................................86
13 DELIVERY......................................................................................................................86
14 ORDER FORM................................................................................................................86
CONCRETE AND REINFORCED CONCRETE PIPES..................................................88
1 GENERAL..........................................................................................................................88
2 MANUFACTURING OF CONCRETE AND REINFORCED CONCRETE PIPES. 88
2.1 Vertical Casting and Vibration Method........................................................................88
2.2 Spinning Method..............................................................................................................88
3 CLASSIFICATION...........................................................................................................89
4 QUALITY AND TESTING OF MATERIALS...............................................................89
5 TYPES OF FITTINGS......................................................................................................90
6 SEALING OF FITTINGS.................................................................................................90
9
7 APPLICATION DRAWINGS AND CALCULATIONS...............................................90
8 SUPPLY OF CONCRETE PIPES...................................................................................91
8.1 Concrete Pipes without Steel...........................................................................................91
8.2 Reinforced Concrete Pipes..............................................................................................92
8.3 Coated Concrete and Reinforced Concrete Pipes.........................................................92

8.3.1 Concrete and Reinforced Concrete Pipes....................................................................92
8.3.2 Coated Concrete and Reinforced Concrete Pipes........................................................93
8.4 Repair of Defects..............................................................................................................94

8.4.1 Method I Manual Repair with Mortar..........................................................................94
8.4.1 .1 Preparation of Surfaces to be Repaired....................................................................94
8.4.1.2 Placement of Mortar.................................................................................................95
8.4.1.3 Method II Repair by Using Mortar Applied by Pressure (MABP)...........................95
8.4.1.3.1 Preparation of the Surface to be Repaired.............................................................95
8.4.1.3.2 Placement of Mortar..............................................................................................96
8.4.1.4 Method III Repairs by Using Bonding Mortar with Epoxy Resin...........................96
9.1 Waterproofing..................................................................................................................97
9.2 Resistance of Pipes...........................................................................................................97
9.3 Cost of Tests......................................................................................................................97
10 MARKING.......................................................................................................................97
11 CONTENT OF OFFER...................................................................................................97
12.1 Acceptance......................................................................................................................98
12.3 Rejection.........................................................................................................................98
13 DELIVERY......................................................................................................................98
14 ORDER FORM................................................................................................................98
10
PRE-STRESSED REINFORCED CONCRETE PIPES WITH STEEL JACKETS
(PRCSJ).................................................................................................................................100
1 GENERAL PROVISIONS..............................................................................................100
1.1 References and Standards.............................................................................................100
1.2 Classification..................................................................................................................100
1.3 Characteristics................................................................................................................101
1.3.1 External Appearance..................................................................................................101
1.3.2 Structural Characteristics...........................................................................................101
1.4 PRCSJ Design.................................................................................................................101
2 PIPE FITTINGS..............................................................................................................102
3 SPECIAL FITTINGS AND PIPES................................................................................102
4 FABRICATION...............................................................................................................102
5 TYPE OF PIPES AND SPECIAL PARTS....................................................................103
5.1 Type of Pipes..................................................................................................................103
5.2 Special Pipe Parts...........................................................................................................103
5.3 Welding for Special Fittings Fabrication.....................................................................103
6 PIPELINE ROUTE.........................................................................................................104
7 SPECIAL FITTINGS TO BE USED IN THE PIPELINE...........................................104
8 PROTECTION AGAINST ABRASION.......................................................................104
9 TESTING AND OBSERVATION..................................................................................105
9.1 Cost of Tests....................................................................................................................106
9.2 Technical Inspection......................................................................................................106
10 MARKING.....................................................................................................................106
11 PACKAGING.................................................................................................................106
12 CONTENT OF OFFER.................................................................................................106
13 ACCEPTANCE - CONDITIONAL ACCEPTANCE - REJECTION......................107
11
13.1 Acceptance....................................................................................................................107
13.2 Conditional Acceptance...............................................................................................107
13.3 Rejection.......................................................................................................................107
14 DELIVERY....................................................................................................................107
15 ORDER FORM..............................................................................................................107
16 HANDLING AND STORAGE.....................................................................................107
17 TRANSPORT AND STORAGE...................................................................................108
HARD POLYVINYL CHLORIDE (PVC) PIPES.............................................................109
1 GENERAL PROVISIONS..............................................................................................109
1.2 Technical Characteristics..............................................................................................109
1.3 PVC Pipes for Pressure Applications...........................................................................110
1.4 PVC Pipes for Non-pressure Applications..................................................................110
1.5 General Characteristics.................................................................................................110
2 SAMPLING, INSPECTION AND TESTS....................................................................111
2.1 Sampling, Pressure and Impermeability Test.............................................................111
2.2 Cost of Tests....................................................................................................................111
3 MARKING.......................................................................................................................111
4 PACKAGING...................................................................................................................111
5 DELIVERY, TRANSPORT AND STORAGE OF PIPES...........................................112
6 CONTENT OF OFFER...................................................................................................112
7.1 Acceptance......................................................................................................................113
7.3 Rejection.........................................................................................................................113
8 DELIVERY......................................................................................................................113
12
8.1 Place of Delivery.............................................................................................................113
9 ORDER FORM................................................................................................................113
10 TECHNICAL INSPECTION.......................................................................................114
POLYETHYLEN (PE) PIPES.............................................................................................115
1 GENERAL........................................................................................................................115
1.1 Scope................................................................................................................................115
1.2 Standards........................................................................................................................115
1.3 Pipe Specifications.........................................................................................................115
1.4 Raw Materials................................................................................................................116
1.5 Technical Specifications................................................................................................116
1.6 Pipe Jointing Methods...................................................................................................117

1.6.1 Butt Welding..............................................................................................................118
1.6.1.1 Butt Welding Requirements....................................................................................118
1.6.1.2 Butt Welding Procedure......................................................................................118
1.6.2 Electro-fusion Welding.......................................................................................118
1.6.2.1 Electro-fusion Welding Requirements................................................................119
1.6.2.2 Electro-fusion Welding Steps.............................................................................119
1.6.2.3 Spigot Joints........................................................................................................119
1.6.2.4 Flanged Joints.......................................................................................................119
2 SAMPLING, INSPECTION AND TESTS....................................................................120
2.1 Sampling.........................................................................................................................120
2.2 Tests.................................................................................................................................120
2.2.1 Resistance...........................................................................................................120
2.2.2 Cost of Tests...........................................................................................................121
3 MARKING.......................................................................................................................121
4 PACKAGING...................................................................................................................121
5 DELIVERY, TRANSPORT AND STORAGE OF PIPES...........................................121
6 CONTENT OF OFFER...................................................................................................122

13
7.1 Acceptance......................................................................................................................122
7.3 Rejection.........................................................................................................................123
8 DELIVERY......................................................................................................................123
8.1 Place of Delivery.............................................................................................................123
9 ORDER FORM................................................................................................................123
10 TECHNICAL INSPECTION.......................................................................................123
1 CATHODIC PROTECTION SYSTEM........................................................................124
1.1 General.......................................................................................................................124
1.2 Cathodic Protection Surveys and Application Drawings......................................125
1.3 Preparation of Application Drawings.....................................................................126
1.4 Cathodic Protection Life...............................................................................................129
1.5 Submission of Project to Employer for Approval.......................................................130
1.6 Material and Equipment...............................................................................................130

1.6.1 Anodes.......................................................................................................................130
1.6.1.1 Auxiliary Anodes................................................................................................130
1.6.1.2 Galvanic Anode System......................................................................................130
1.6.1.3 Magnesium Anodes............................................................................................130
1.6.2 External Current Source System................................................................................131
1.6.2.1 Titanium Anodes Coated with Mixed Oxide......................................................131
1.6.2.2 Iron-Silicon Anodes............................................................................................132
1.6.2.3 Anode Bed Material............................................................................................133
1.6.2.4 Galvanic Anode System Anode Bed Material...................................................133
1.6.2.5 Anode Bed Material for Magnesium Anodes....................................................133
1.6.2.6 External Current Source System Anode Bed Material......................................133
1.6.2.7 Anode Material for Mixed Oxide Coated Titanium Anodes.............................133
1.6.2.8 Anode Bed Material for Iron-Silicon Anodes....................................................133
1.6.3 Transformator- Rectifier (T/R) Unit..................................................................134
1.6.3.1 External Current Source System.........................................................................134
1.6.3.2 T/R Unit for Mixed Oxide Coated Titanium Anodes.........................................134
1.6.4 T/R Unit for Iron-Silicon Anodes......................................................................135
1.6.5 Measurement Boxes...........................................................................................136
1.6.5.2 Measurement Boxes for Mixed Oxide Coated Titanium Oxide Anodes............136
1.6.5.3 Measurement Box for Iron – Silicone Anodes...................................................136
1.6.6 Cables.........................................................................................................................136
14
1.6.6.1 Electrical Isolation (Isolated Flange Gasket Set)................................................136
1.6.7 Production and Mounting..................................................................................137
1.6.7.1 Mounting of Anodes...........................................................................................137
1.6.7.2 Galvanic Anode System......................................................................................137
1.6.7.3 Mounting of Galvanic Anodes............................................................................137
1.6.7.5 Mounting of Mixed Oxide Coated Titanium Anodes Karma.............................137
1.6.7.6 Mounting of Iron-Silicone Anodes.....................................................................138
1.6.8 Mounting of Transformer/Rectifier Unit...........................................................138
1.6.9 Mounting of Measurement Boxes......................................................................139
1.6.9.1 Mounting for Galvanic Anode System...............................................................139
1.6.9.2 Mounting for External Current Source System..................................................139
1.7 Mounting of Cables........................................................................................................139
1.8 Excavation and Filling Works......................................................................................139
1.9 Interaction with Surrounding Buildings......................................................................140
1.10 Transition and Acceptance..........................................................................................140

1.10.1 Transition and Acceptance of Galvanic Anode System.....................................140
1.10.2 Transition and Acceptance of External Current Source System.........................140
1.11 Cathodic Protection System Tests...............................................................................141
1.12 Cathodic Protection System Signalization.................................................................142
1.13 Works after Temporary Acceptance..........................................................................143
PIPE LAYING WORKS......................................................................................................144
1 EXCAVATION AND BACKFILLING.........................................................................144
1.1 Trench Depths...........................................................................................................144
1.2 Trench Widths...........................................................................................................144
1.3 Trench Bottom..........................................................................................................145
1.4 Pipe End Pits.............................................................................................................145
1.5 Road Pavements........................................................................................................145
1.6 Trench Fillings..........................................................................................................145
1.7 Preparation of Pipes at Trench Side.......................................................................145
2 LAYING OF CONCRETE PIPES, REINFORCED CONCRETE PIPES AND

STEEL PIPES COATED WITH CONCRETE.................................................................146
2.1 Pipe Laying – General..............................................................................................146
2.2 Granulated Material for Pipeline Bed....................................................................146

15
2.3 Laying of Concrete Pipes..........................................................................................147
2.4 Impermeability Barrier for Pipelines with Granulated Cushion.........................147
2.5 Pipe Jointing..............................................................................................................148
2.6 Pipes Passing through Structures............................................................................149
2.7 Connection to Existing Pipes....................................................................................149
2.8 Test and Cleaning of Pipelines.................................................................................149

2.8.1 Pipeline Test– General.............................................................................................149
2.8.2 Implementation and Workmanship.....................................................................150
2.9 Cleaning of Pipeline..................................................................................................150
3 LAYING OF STEEL PIPES AND REINFORCED CONCRETE PIPES WITH

STEEL JACKET..................................................................................................................151
3.1 Welding of Pipeline...................................................................................................151
3.2 Materials........................................................................................................................151
3.3 Welding Methods..........................................................................................................151
3.4 Welding Procedure Qualification................................................................................152
3.5 Qualification of Welders and Welding Operations.................................................152
3.6 Welding Preparation..................................................................................................152
3.7 Welding......................................................................................................................153
3.8 Cleaning after Welding..........................................................................................153
3.9 Post Weld Heat Treatment.........................................................................................153
3.10 Numbering of Weld Seams.......................................................................................154
3.11 Coating of Weld seams...............................................................................................154
3.12 Closing of Pipe Ends....................................................................................................154
3.13 Post Weld Process.....................................................................................................154
3.14 Tests............................................................................................................................154
3.15 Application.................................................................................................................155
3.16 Cleaning of Expropriation Area..............................................................................155
3.17 Leveling and Trench Excavation.............................................................................155
3.18 Use of Excavation Material......................................................................................155
16
3.19 Discharge of Water during Construction...............................................................155
3.20 Pipe Trench Filling...................................................................................................156
3.21 Pipe Lowering and Laying...................................................................................156

3.21. 1 Examination of Pipes before Laying.......................................................................156
3.21.2 Lowering of Pipes into Trench..............................................................................157
3.21.3 Laying of Steel Pipes..........................................................................................157
3.21.4 Minimum and Maximum Soil Cover for Steel Pipes..........................................157
3.22 Bends..........................................................................................................................157
3.22.1 Elastic Bends.......................................................................................................158
3.22.2 Field Bends.........................................................................................................158
3.22.3 Factory Made Bends..........................................................................................159
3.22.4 Tees and Y's......................................................................................................160
3.23 Cutting of Pipe Heads...............................................................................................160

3. 23.1 Connection of Pipe Heads..................................................................................160
3. 24 Other Jointing Methods.......................................................................................161

3.24.1 Threads................................................................................................................161
3.24.2 Flanged Joints...................................................................................................161
3. 25 Pipeline Tests..............................................................................................................162
3.25.1 Hydrostatic and Impermeability Test of Completed Pipeline............................162
3.25.2 Pressure Test.....................................................................................................162
3.25.3 Tests........................................................................................................................162
3.25.4 Cleaning of Pipeline...............................................................................................163
3.25.5 Welding Inspection.............................................................................................163
3.25.6 Scope of Examination............................................................................................163
3.25.7 Production Tests................................................................................................164
4 LAYING OF ASBESTOS CEMENT PIPES................................................................165
4.1 Pipe Laying................................................................................................................165
4.2 Deviation from Axis..................................................................................................165
4.3 Trench Width............................................................................................................166
4.4 Trench Fillings..........................................................................................................166
4.5 Acceptance Test of Laid Pipes.................................................................................166
5 LAYING OF CAST-IRON DUCTILE PIPES..............................................................168
5.1 Straightening and Cutting of Pipes.........................................................................168
5.2 Trench Excavation....................................................................................................168
5.3 Bedding of Pipes........................................................................................................169
5.4 Laying and Jointing of Pipes....................................................................................169

17
5.5 Fixing Masses............................................................................................................171
5.6 Retaining Wall...........................................................................................................172
5.7 Clamped Joints..........................................................................................................172
5.8 Filling around Pipes..................................................................................................173
5.9 Backfilling..................................................................................................................174
5.10 Equipment.................................................................................................................174
5.10.1 Dismountable Joints..........................................................................................174
5.10.2 Surface Boxes...................................................................................................174
5.10.3 Flanged Anchoring Sleeves..............................................................................174
5.11 Pipe Support..............................................................................................................174
5.12 Marking Posts of Route............................................................................................175
5.13 Corrosion Protection................................................................................................175
5.14 Testing of Pipeline.....................................................................................................175
5.15 Cleaning of Pipeline..................................................................................................177
6 LAYING OF PVC, CTP PIPES.....................................................................................177
6.1 Laying of Pipes..........................................................................................................177
6.2 Pipe Trenches............................................................................................................179
6.3 Pipe Connections.......................................................................................................179
6.4 Testing of Constructed Pipeline...............................................................................180

6.4.1 Length of Pipeline..............................................................................................180
6.4.2 Supporting and Fixing of Pipeline....................................................................180
6.4.3 Filling of Pipeline....................................................................................................181
6.4.4 Manometer Installation.....................................................................................181
6.4.5 Preliminary Test..................................................................................................181
6.4.6 Water Leakage....................................................................................................181
6.4.7 Main Test............................................................................................................181
6.4.8 Connection Places of Partial Pipelines...............................................................182
6.4.9 Activation of Pipeline.........................................................................................182
7 THE LAYING OF PE AND HDP PIPES......................................................................182
7.1 Laying of Pipes..........................................................................................................182
7.2 Calculation Methods.................................................................................................183
7.3 Effect of Temperature..............................................................................................183
7.4 Testing of Constructed Pipeline...............................................................................184

7.4.1 Length of Pipeline...............................................................................................184
18
7.4.2 Supporting and Fixing of Pipeline......................................................................184
7.4.3 Filling of Pipeline.....................................................................................................184
7.4.4 Manometer Installation.......................................................................................184
7.4.5 Preliminary Test..................................................................................................184
7.4.6 Water Leakage....................................................................................................185
7.4.7 Main Test............................................................................................................185
7.4.8 Connection Places of Partial Pipelines...............................................................185
7.4.9 Activation of Pipeline.........................................................................................185
19
STEEL PIPES
1 SUBJECT AND SCOPE
This Specifications describes the technical characteristics as well as control and

inspection methods and acceptance criteria for spiral-welded steel pipes coated with cement
mortar inside that is harmless to health and polyethylene outside or with polyethylene outside
and epoxy inside. These steel pipes shall be used for the water supply pipeline by the General
Directorate of State Hydraulic Works (Employer).
Steel pipes shall be manufactured and tested according to the requirements of this
Specifications and its annexes, and specifically to the TSE, DIN and AWWA standards of
relevance to the subject matter, or their equivalents acceptable to the Employer, whether or
not their numbers are shown in this Specifications or its annexes.
2 STEEL MATERIAL CHARACTERISTICS
2.1 Materials
Unalloyed steel bands or rolled steel sheets of grade Fe 44 shall be used for the
manufacturing of pipes.
Steel pipes shall be manufactured and tested in accordance with TS 1997, TS 346, TS
416, ISO 4200, ISO 2604 standards.
2.2 Chemical Composition
Steel quality shall be grade Fe 44, as determined by TS 1997.
Chemical composition of the steel shall be as follows:
Carbon, maximum : 0.21%

Phosphor, maximum : 0.04%
Sulphur, maximum : 0.04%
2.3 Mechanical Characteristics
Mechanical characteristics of the steel pipes shall be as given in Table 1. The

minimum yield and ultimate strength values shall also apply to the weld seams.
20
TABLE 1
UPPER YIELD
STRENGTH ULTIMATE ULTIMATE EXTENSION
STEEL MATERIAL STRENGTH % MIN.
REPRESENTATION NO
kgf/mm² N/mm²
MIN. Longitudinal Transverse
kgf/mm² N/mm²
Fe 37 1.0254 23,5 235 35 - 48 350-480 25 23
S = Pipe Wall Thickness (mm) bending angle = 180º
Mechanical characteristics shall be as follows:
 SMYS* for wall thickness less than 16 mm : 27.5 kgf/mm2

SMYS for wall thicknesses between 16 and 40 mm : 26.5 kgf/mm2
SMTS **, in all cases : 42-55 kgf/mm2
Longitudinal extension : 21%
Transverse extension : 19%
Mandrel for bending test : 3 x wall thickness
*SMYS : Specified Minimum Yield Strength

**SMTS : Specified Minimum Tensile Strength
Allowable service pressure shall be 16 bar and maximum working temperature shall
o
be 300 C.
3 PIPE MANUFACTURING
3.1 Manufacturing
Pipes shall be manufactured from rolled strips or bands using double sided submerged,
pressure electric, gas induction and other welding types.
Pipes shall be welded in such a way that the weld seams will be continuous, and the
work of welding shall be perfect. For pipes, pressure up to 90% of the theoretical tension
allowed for weld seam during impermeability test with internal pressure shall be used.
The manufacturing method and issues to be considered in manufacturing of these

pipes under this specifications are given in DIN 1626.
The Employer shall be free to choose a standard equivalent to DIN 1626 instead of it
or a manufacturing method equivalent to that shown in DIN 1626.
The manufacturing process shall be as follows:
For pipes DN ≤ 300 mm, seamless or gas shielded (HFI) welded pipes can be
accepted.
For pipes 300 mm < DN < 500 mm, seamless or spiral welded pipes can be accepted.
21
For pipes DN > 500 mm, spiral welded pipes can be accepted.
Heat treatment shall be applied to all cold finished pipes, and to the weld zones of
electric resistance or induction welded pipes.
Sheet and plate steel shall be shaped by rolling or pressing, width adjustment of sheet
and plate shall be permitted.
Repairs by welding are not permitted in:
 Parent materials
 Seamless or HFI welded pipes.
 Cracks in weld seams.
Other defects in the weld seams shall be repaired in accordance with an approved weld
repair method, and subsequently radiographed.
Jointers and girth welds shall not be permitted.
Finishes of all the elements shall be completed, and the elements shall have no visible
defects and pass all the specified tests. Butt welded, electric resistance and induction welded
elements shall not include welds used for joining lengths of strip steel. Skelp-end welds if
required on spiral pipe shall be as close to the middle of the pipe as possible and never closer
to the pipe ends than 3 x nominal pipe diameter.
3.2 Weld Seam
Weld seam shall be clean, uniform and have a homogeneous structure, as well as free
from cracks, blisters, cavities and accumulation. Binding of the weld material to the parent
material should be good. The Company shall indicate in its offer the proposed welding
method for pipe manufacturing. There should no shape deformations that can degrade the
circularity of the pipe near the weld seam during folding of strips and bands.
3.2.1 Post Weld Process
Heat treatment shall be applied to the pipes welded, and the welding burrs shall be
cleaned. DIN 1626 requirements shall be complied with.
3.3 Dimensions and Dimension Tolerances
3.3.1 Dimensions
The outside diameters and wall thicknesses, length and quantities of the pipes are
given in the attached list. Dimensions shall correspond to the values given in this list.
3.3.2 Pipe lengths
22
For pipes up to 406 mm in diameter, pipe length shall be 8 m, and pipes with larger
diameter, pipe length shall be 6 m.
3.3.3 Tolerances
Pipe length tolerances are summarized in the Table below:
Length D = up to 500 m D = larger than 500 m

Up to 6 m + 10 mm + 25 mm
0 0
between 6 – 12 m + 15 mm + 50 mm
0 0
For pipe length tolerances, DIN 1626 values shall be taken as basis.
3.3.4 Outside Diameter and Tolerances

At pipe body and pipe end: 114,3 < outside diameter <406 ± (0,5% outside diameter +
1) mm
3.3.5 Wall Thickness and Tolerances

In the range of 3,2 < s < 5: + 0,45 mm
- 0,25 mm
Upper tolerance is determined by weight tolerance. S= wall thickness (mm)
3.3.6 Weld Seam Height Tolerance

If pipes are manufactured by fusion welding, for the fusion welded pipes, weld seam
height (dy) shall not exceed by wall thickness (s) the values given below.
s < 5 mm dy = 2,5 mm
If pipes are manufactured by pressure welding, for the electric pressure welded pipes,
weld seam height shall not exceed 0.3 mm inside the pipe after the post weld surface
treatment. For the pressure welded pipes, inside weld seam height should not be more than 0.3
mm + 0.5 s (s: wall thickness).
3.3.7 Pipe End Tolerances

Pipe ends shall be cut in such a way that the pipe will have a vertical cross section, and
edges for welding shall be prepared in accordance with DIN 2559. Edges for welding shall be
smooth and free from burrs and indentation. Pipe ends shall be at an angle of 30° and edges
for welding shall be (1,6 mm + 0.8 mm).
23
3.3.8 Tolerance Class and Certification
Tolerances of the pipes larger or equal to 500 mm shall be marked as shown below.
TOLERANCE CLASS (mm) SYMBOL

-1.6 to -0.8 -
- 0.8 to +0.8 0
+0.8 to +1.6 +
Inside diameters of the pipe ends shall be determined according to their circumference
and shall be included in the appropriate tolerance class, accordingly. Then the corresponding
symbol shall be marked on both ends using a template.
Pipe certification documents shall comprise Manufacturer’s Certified Test Reports and
inspection certificate (certified to DIN 50059-3 1B or equivalent) and, if necessary,
Independent Inspector Reports and third party approval certificates, all marked with the
supply contract number and containing:
 Heat and product analysis results,

 Mechanical tests results,
 Non destructive examination reports with a statement of method used,
 A report verifying compliance with visual and dimensional checks and with material.
 Statement of manufacturing process and type of heat treatment.
 A report verifying compliance with hydrostatic test requirements including test
pressure.
 Inspection certificates and reports for surface treatments.
3.4 Weights
Pipe weights, G (ton/m):

Inside diameter (mm) + wall thickness (mm) . . . . . (1)
Specific weight = 8.00 ton/m3 . . . . . . . . . . . . . . . . . (2)
Unit length = 1 m . . . . . . . . . . . . . . . . . . . . . . . . . . (3)
Wall thickness (mm) . . . . . . . . . . . . . . . . . . . . . . . . (4)
Weight shall be calculated using the following formula: G = 3.14 x (1) x (4) x (2) x 10 -6
(ton/m). The payment transactions shall be based on the weight (except the weight of the
isolation material).
Deviation limits from the weights calculated above shall be as follows according to DIN
1626;
Weight tolerance for a single pipe : Upper limit (%) +12

Lower limit (%) – 8
For a consignment of minimum 10 tons : Upper limit (%) + 10
Lower limit (%) - 5
24
3.5 Pipe Straightness
Deviation from a straight line shall not be more than 1.5 mm at every 1 m. Pipe ends
shall be cut perpendicular to the pipe axis.
3.6 Ovality
Pipes shall be as circular (round) as possible. Deviation from circularity shall

be minimum 1%.
3.7 Surfaces
Both internal and external surfaces of the pipes shall be brilliant, clean and smooth as
required by the manufacturing method used.
Surface defects like such as scrapes, scales, cracks, burrs, plication, and pitting shall
be remedied following an appropriate procedure. During surface treatment, the wall thickness
tolerances for the pipe shall certainly be taken into consideration.
When wall thickness is within the dimension tolerance limits and the pipe usability is
affected, some projections and indentation, scrapes, or visible differences in some parts of the
surface due to manufacturing method may be permitted.
However, differences (variations in wall thickness) shall not be permitted if result in

hesitation about the pipe usability, regardless of compliance with the specified limits.
Total penetration, cracks and non-metallic large particles as well as other unacceptable
defects at weld zones shall not be permitted.
Fusion of the pipe material with the welding material shall be complete and weld
seams shall be provided at both internal and external surfaces.
DIN 1626 requirements in addition to those prescribed herein shall be complied with
regarding the form and appearance of weld seams. As for the pipe surface structure and
appearance, DIN 1626 requirements shall be complied with.
3.8 Marking of Pipes and Special Parts
The following markings shall be made on each pipe in such manner that they will be
legible and non-erasable.
- Company’s business title
- Representation and number of the standard (TS 1997, etc.)
- Material grade
- Outside diameter (mm) and wall thickness (mm)
- Pipe length
- On each pipe face, the word “Employer” shall be written in letters of minimum 1/4 of
the nominal pipe diameter
- The company’s business title shall not be written in letters bigger than 5 cm.
25
4 ISOLATION OF STEEL PIPES
Three-fold coating shall be applied for the pipe coating in accordance with the DIN
30670 requirements as described below.
4.1 Cleaning of Pipe Surfaces

Prior to coating, pipe surfaces shall be thoroughly cleaned to remove rust, dirt, grease,
dust, and other extraneous substances by sandblasting to quality Sa 2 1/2 Sa 3.
4.2 Isolation of Pipe External Surfaces

Pipes shall be protected against harmful impacts of soil and underground water by an
external coating in accordance with the requirements prescribed in this specifications and its
annexes and with the relevant standards.
External coating should, at minimum, have the following characteristics:
It should be an effective electrical insulator;

It should be easily applied;
It should adequately adhere to the pipe surface;
It should not produce pores in the course of time;
It should be resistant to forces and impacts during storage, transportation and laying;
It should not loose its electrical resistance in the course of time;
It should be easily repairable.
Cathodic protection of supply pipes against external impacts shall not mean a
reduction in the importance of isolation.
4.2.1 External Coating
4.2.1.1 Epoxy Coating
Pipes shall be heated by induction in the induction furnace up to 180 – 220 °C

temperature so that epoxy powder paint is kiln-dried. (This process must be carried out in an
induction furnace. At LPG furnaces, there is a risk that hydrocarbon and soot deposits can
stick on the pipe surfaces. Such materials prevent sufficient adherence of the coating to the
pipe surface.)
During that process, in order to protect the quality of the steel, the pipe temperature
shall be controlled by infrared temperature sensors. Following these operations, electrostatic
epoxy powder coating approximately 70 um in thickness shall be applied.
4.2.1.2 Copolymer Layer Application
Copolymer layer application shall be performed during curing period of Epoxy paint
following performance of the issues specified in Article 4.2.1.1.
26
The copolymer material to be used shall be of material that provides an optimal
adherence force between Epoxy coating layer and polyethylene coating to be applied, and it
shall be applied as a layer approximately 300 um in thickness.
4.2.2 Polyethylene Coating
Polyethylene coating shall be applied on the pipe surface by using profile extrusion
method. If the coating of the required materials by profile extrusion method is not possible,
the coating shall be performed by wrapping method. When applied, both coating methods
shall be as defined in DIN 30670 norm.
4.2.2.1 Polyethylene Coating Thickness

External coating of the buried pipes shall be made by polyethylene wrapping in
accordance with TS 5139 or DIN 30670.
Protective layer thickness on the pipe is measured with an accuracy of 0,1 mm
Coating thickness on the pipes shall correspond to the values given below, unless
otherwise specified.
PIPE DIAMETER MINIMUM COATING

THICKNESS (mm)
DN 100 mm 3 mm
Between DN 100 and DN 250 3 mm
mm
Between DN 250 and DN 800 4 mm
mm
Unless otherwise specified, coating of the pipes between DN 100 and DN 800 in
diameter shall be peeled of after coating to allow a 50 mm wide welding.
4.2.3 Bitumen-based Isolation
Isolation described below shall be in accordance with German DVGW (Deutscher

Verein von Gas-und wasser fachmaenner e.V) GV5 and GV6 standards or with AWWA
(American Water Works Association) C-203 Standard.
External isolation shall be applied with a bitumen-based material approved by the

Employer. Fiber glass or a similar material that does not decay or become fibrous shall be
used and thickness of the isolation layer shall be 4 mm However, for some points, exceptions
can be allowed locally by the written permission of the Control Engineer and, for such cases,
thickness of the isolation layer can not be less than 3.5 mm. Before coating, external surfaces
of the pipes shall be carefully cleaned from tinder layers, rust and similar substances and shall
be polished by sandblasting, or equivalent applicable to the Employer.
Note: If it is required by the Employer, the external isolation shall be done made with
bitumen-based fiber glass.
27
4.3 Internal Isolation of Steel Pipes
4.3.1 Internal Isolation of Small Diameter Pipes

For pipe fittings up to 150 mm nominal diameter (150 mm inclusive) shall be hot-dip
galvanized. Parasites, rust, dirt on the elements shall be thoroughly cleaned before
galvanizing. Galvanizing shall be made by dipping in a bath containing minimum 98.5%
melted zinc by weight. All the surfaces of the elements homogeneously coated by sticky zinc
shall pass from an accepted copper sulphate solution dipping test. Galvanizing shall be made
on the surfaces before threading and jointing.
For small diameter pipes where internal coating can not be applied as concrete, an
epoxy internal coating can be made upon the request of the Employer.
4.3.2 Internal Coating of Pipes
The purpose of the internal coating is to prevent corrosion and reduce the load losses.
Coating material shall be water resistant (not soluble in water), it shall not give any taste or
odor to water, and it shall not be detrimental to public health. Verification by the certificates
of relevant institutions shall be made to show that the material is harmless to public health.
Internal isolation shall be in accordance with AWWA 205 (Cement Mortar Protective
coating add coating for steel water pipe) or equivalent.
Use of other coating types than the cement mortar coating mentioned above shall be
subject to the Employer’s approval and coating shall be made according to the related
standards. Before coating, internal surfaces of the pipes shall be carefully cleaned from all
types of tinder layers, rust and similar substances and shall be polished by sandblasting, or
equivalent applicable to the Employer.
4.3.3.2 Coating of Pipe Internal Surfaces Using Concrete with Special Additive
4.3.3.2.1 Scope
This method describes the conditions for the application method and quality
requirements for coating of the internal surfaces of the steel pipes using concrete with special
additives.
4.3.3.2.2 Description
Special additive is the combination of minerals reacting with cement and acrylic resin
distribution resistant to soaping; in addition to this, it includes binder fillers and water
retaining active materials.
What is aimed with the use of special additives in the concrete mortar is to:
Provide adherence of the concrete coating to the steel surface;
Reduce shrinkage cracks and thermal stress;
Allow application with thinner layers than mostly used concrete coatings; and
Reduce curing period of the concrete coating.
28
4.3.3.2.3 Application Method and Necessary Equipment
Concrete with special additives shall be applied using coating, spraying and spinning
methods. Generally mortar is applied by the spraying equipment. This equipment consists of
the following parts:
Compressor,
Special conveyor equipment,
Special spraying equipment,
Mortar machine,
Mortar pump.
The equipment shall include all accessories so that pipes having a diameter of
mm can be used.
Surface Preparation:
The surface to be coated shall be free from loose rust, parasite, grease, paint and other
dirt. Cleanness grade st-2 as defined in DIN 5592 Section 4 shall be sufficient. Unavoidable
minor rusts due to hydrostatic pressure test of the pipes do not provide any inconvenience for
this method.
Material Quantity for 1.00 m2 according to Steel Pipe Internal Isolation Thickness:
Isolation thickness Cement Material Quantity (kg)

Quartz Sand Water Special Additives
For 3 mm 2.100 4.200 0.600 0.750
For 4 mm 2.800 5.600 0.800 1.000
For 5 mm 3.500 7.000 1.000 1.250
Losses are included in these quantities.
For pipes < 1000 mm in diameter, isolation thickness shall be 3 mm; this shall be
verified by the tests and, if necessary, coating channels shall be readjusted according to
diameters.
4.3.3.2.4 Concrete Coating Adherence and Strength Characteristics
Adherence shall be minimum 1.5 N/mm² (for 28 days) in accordance with ZIV SIB
87.
Compressive strength shall be minimum 50 N/mm² (for 28 days) in accordance with
DIN 1164.
Tensile strength at bending shall be minimum MO N/mm² (for 28 days) in accordance
with DIN 1164.
29
4.3.3.2.5 Coating Surface Smoothness and Layer Thickness
Coating surface shall be smooth as much possible and free from undulation, cratering
and deep traces.
All types of topographical differences shall be within + 1 mm.

Equivalent sand roughness on the surface shall be Ks = 0.1 mm maximum.
Primarily, there shall be no creamy layer on the surface. However, a creamy layer less than
0.5 mm in thickness can be acceptable.
Coating shall essentially be free from cracks and voids.
However, local capillary cracks can be acceptable, provided that there is no space between
coating and the steel surface.
When hardened, the concrete coating surface shall be firm enough to resist to wear under
friction.
Layer thickness shall be nominal 14 mm.
Minimum individual value: 2.5 mm

Minimum average value: 3.0 mm
Maximum individual value: 6.0 mm
Individual and average values are defined for a cross section plane.
4.3.3.2.6 Pipe Ends

For pipes with a weld edge, no coating shall be made in a zone extending around 25
mm from the pipe end. Coating may end as a sharp edge, or by diminishing gradually. If
coating ends by diminishing gradually, it may fall below the minimum individual coating
thickness provided for. However, the length of the zone, where the coating diminishes
gradually (i.e., transmission zone) shall not be more than 100 mm.
4.3.3.2.7 Concrete Coating Adherence and Strength Characteristics
Adherence:
It shall be minimum 1.5 N/mm2 (for 28 days) in accordance with ZTV SIB 87.
Compressive Strength:
It shall be minimum 50 N/mm2 (for 28 days) in accordance with DIN 11642.
Tensile Strength at Bending:

It shall be minimum 10 N/mm2 (for 28 days) in accordance with DIN 1164.
4.3.3.2.8 Proof of Quality
To prove that the concrete coating provides the quality requirements anticipated with
this method, at least the following tests and controls shall be performed and documented.
Each pipe shall be subjected to measurement and visual inspection with respect to layer
thickness, surface quality, cracks and voids.
30
For each sand supply, sieve analysis shall be made and cleanness grade shall be determined.
Mix ratio, water-cement value shall be determined for mortar at least once a week if
production parameters remain the same.
For each consignment of special additive supply, soaping strength value shall be determined.
Adherence and strength tests for 7 days, 14 days and 28 days shall be made on 3 different
pipes selected from a batch of around 500 pipes if production parameters remain the same.
4.3.3.2.9 Internal Isolation of Drinking water Pipes

Internal surfaces of the pipes shall be coated in accordance with DIN 2614 and
AWWA C 205. Internal surfaces of the water supply pipes shall be coated with a cement
mortar mixed in a concrete mixer and prepared with Portland cement with admixtures that
comply with TS 19, normal sand that complies with TS 2717 and water. Water cement ratio
shall not exceed 0.42.
Cement mortar coating shall be applied using a centrifugal method and shall have the
thicknesses and tolerances given below:
Nominal Diameter Coating thickness (mm) Tolerance (mm)

(mm)
250 – 580 8 - 1.6 / + 3.2
600 – 900 10 - 1.6 / + 3.2
More than 900 13 - 1.6 / + 3.2
5 SAMPLING, INSPECTION AND TESTS
5.1 Sampling
Inspection shall be carried out with pipes of the same steel and of the same size
batched as follows by diameter and provided at one time:
pipes < 500 mm . . . . : 100 pipes or up to 100 pipes
pipes > 500 mm . . . . : 50 pipes or up to 50 pipes
5.1.1 Separation of Samples

A test part shall be cut perpendicular to the weld seam and along the pipe axis of the
sample pipe having an outside diameter of 500 mm. Heat treatment shall not be applied on the
test part and it shall not be flattened within the measurement length. For larger sample pipes
having a diameter more than 500 mm, a test part perpendicular to the weld seam shall be cut,
with the latter in the middle, together with a second flat test part whose length is
perpendicular to the pipe axis.
Test parts shall be cold flattened and, if necessary, they can be annealed at a
temperature under 500 °C. For tensile test, short proportion test part (5 do) shall be cut.
For bending tests of the fusion-welded pipes, two test parts shall be cut perpendicular
to the weld seam of the sample pipe, with the weld seam in the middle. Before tests, the test
parts can be kept at a temperature of 250 °C for 6 hours for removal of the hydrogen.
31
5.1.2 Material Tests
For destructive testing, one pipe shall be selected from each batch as described below
and it shall undergo a heat treatment at 250o C 6 hours before the test:
Tensile tests shall be made on a sample cut from the parent material, as well as a sample cut
perpendicular to weld seam, with the latter in the middle.
Bending tests shall be made on a sample cut, with the weld seam in the middle. Bending test
shall be made by bending the sample, e.g., through 180 o, around a mandrill having a diameter
three times the pipe wall thickness. After bending, the sample shall show no crack in the weld
material, or between weld material and parent material, with a dimension more than 3 mm.
Alternatively, if cracking or fracture occurs, the sample shall be opened and the fracture
surfaces shall be examined. The sample shall be regarded as having passed the test if the
fracture surfaces show no gas pockets or slag having a length more than 2 mm.
Flattening tests: Test rings with a width not less than 38 mm cut from the pipes of nominal
diameter more than 50 mm and up to 150 mm and flattened between parallel plates. Any weld
in the sample shall be positioned at the point of maximum bending, and shall show no sign of
fracturing until the distance between the plates is less than 75% of the original pipe diameter.
No sign of fracture in the parent material shall occur until the distance between the plates is
less than 60% of the pipe diameter.
For non destructive tests, the following shall be carried out:
Hydrostatic tests for all pipes

Surface inspection of all pipes
Non destructive controls of all pipes
Diameter inspection of all pipes
Tensile strength shall be made in accordance with TS 138. Bending tests shall be made
in accordance with TS 205, and the sample shall be bended through 180o.
Non destructive tests shall be in accordance with TS 4822.
Hydrostatic test shall be made at a test laboratory approved by the Employer. The test
shall be made at a room temperature of 20o + 2o and undergo a water pressure of 50 bar for
minimum 5 seconds. Test shall be made before pipe isolation, and test reports shall be
submitted to the Control Engineer for approval. The Contractor shall bear all costs of the
impermeability tests.
5.1.3 Pipe Material Characteristics and Material Tests
5.1.3.1 Steel and Steel Characteristics
Quality, type and material characteristics of the steel to be used for steel pipe
manufacturing shall be in accordance with TS 1997. Characteristics for some steel types are
as follows:
32
Steel Material Max. foreign Ultimate Yield Ultimate Extension
Type No substance ratio in the Strength strength Min. %
steel structure (%) (kg/mm2) (kg/mm2)
C P S min. min. Longitudinal Transverse
Kfe 37 1.0253 0.20 0.04 35-48 23.5 - 25 23
Fe 37 1.0254 0.17 0.04 35-48 23.5 22.5 25 23
Fe 44 1.0256 0.21 0.01 42-55 27.5 26.5 21 19
Fe 52 1.0421 0.22 0.04 50-65 35.5 34.5 21 19
5.2 External Coating Inspection and Tests
5.2.1 Visual Inspection

When finished, visual inspection of the pipe coating shall be made to check for any
torn, crushing, slag or blister.
5.2.2 Control of Coating Adherence to Pipe
Coating adherence to the pipe, i.e., whether it is firm or not, shall be checked making
the test specified in DIN 30670.
5.2.3 Control of Coating Defects
Existence of micro electrical pores on the coating shall be checked making the
electrical control test specified in DIN 30670.
5.2.4 Other Tests

For the pipes coated, such other tests as peeling strength, impact strength, extension
strength due to torn, and notch strength shall be made in accordance with DIN 30670.
5.2.5 General Provisions Regarding External Coating Tests
All external coating tests shall be made at a temperature between 15 – 35 °C. 5 pipes
shall be randomly selected from each batch of pipes manufactured. 10 additional samples
shall be taken from the same batch if one of the samples does not meet the requirements.
Then, if one of those samples taken additionally does not meet the requirements, all the pipes
in the test batch shall be regarded as defective.
5.2.6 Sampling and Tests During Delivery of Pipes
a. Pipes shall be divided into lots and subjected to tests.

b. If the amount of the remaining pipes is less than 50% of a single lot, then these
pipes shall be equally distributed to the lots. If the amount of the remaining pipes is
33
more than 50% of a single lot, or if the amount of the pipes that will be delivered is
less than 50% of a single lot, then that amount shall be regarded as a lot and subject to
normal procedures.
c. Chemical structure of the material to be used for pipe manufacturing is described
in this specifications. Unless otherwise agreed upon, chemical analysis of the steel
shall be made by cutting at least one sample from one pipe for each lot, and the
analysis results shall be compared with the specifications value and the compliance
with the specifications shall be ensured.
d. The Control Engineer shall select at least one pipe from each lot, which will be set up
as described above, and subject it to tensile test. For non destructive tests, two samples
shall be cut from pipes (one sample will be with weld seam in the middle and the other
will be seamless) and tested in accordance with DIN 50120 and DIN 50122.
e. Four folding samples shall be taken from each lot of fusion-welded pipes for
technological tests in accordance with DIN 50121.
As for pressure-welded pipes, pipes in the lot shall be subjected to ring-folding test
each as a technological test. For pipes manufactured individually, two rings from both
pipe ends shall be cut and subjected to test. If, with the manufacturing method used,
pipes are obtained by cutting one big piece from the pipe whose length is several times
the determined pipe length, one ring shall be cut from the one end of the pipe obtained
from the said long pipe and subjected to test.
f. Weld seams of all the manufactured pipes shall be subjected to non destructive tests
(Ultra-sound, magnetic or X-ray tests) along the pipe length. For fusion-welded pipes,
in addition to the weld seam test, test pieces in 200 mm length shall be cut from both
pipe ends or from the zones shown by the Control Engineer, and they shall be x-rayed
by calorification.
g. Both internal and external surfaces of pipes shall be visually inspected.
h. Outside diameter, wall thickness and weld seam dimensions of pipes shall be
measured and controlled.
i. Each pipe shall be subjected to waterproofing test. DIN 1626 requirements shall be
complied with in sampling and testing described above.
j. For testing in accordance with DIN 1626, if the pipes that have undergone tests do not
meet the requirements, they shall be scraped. For the scraped pipe, two additional
pipes shall be taken from the relevant lot and shall be subjected to tests. If both pipes
do not produce the expected results, all pipes in that lot shall be subjected to tests one
by one, and any pipes that do not meet the requirements shall be scraped.
k. After completion of the pipe delivery tests, the Contractor shall draw up a report
(certificate) according to the DIN 50049. Chemical analysis of the steel shall be
submitted to the Employer together with that report. The reports related to non
destructive tests shall be type “B” reports, as drawn up in accordance with DIN 50049.
5.2.7 Inspection and Tests Reports
Inspection and test reports shall include at least the following information.
- The name of the place and laboratory where test is made, as well as the name, position
and occupation of the authorized personnel who have made the tests and signed the
report.
- Date of inspection and test.
- Description of the sample.
- The numbers of the standards followed in the tests and inspections.
- Results.
- Precautions taken to prevent the negative effects of the factors that can change the
34
inspection and test results.
- Compliance with the standard.
- Date and number of the report.
5.3 Characteristics of Manufactured Pipe
The characteristics of the pipe manufactured from the steel whose features are given
above and the delivery tests to be made are detailed in this specifications and in DIN 1626.
5.4 Waterproofing
Pipes should be waterproof.
5.5 Pipe Delivery and Quality Warranty
The Contractor shall guarantee that the materials used and the pipes are in compliance
with the requirements and the relevant standards.
Particularly, manufactured pipes shall be in compliance with the testing requirements

set out in this specifications and the relevant standards.
6 GENERAL DELIVERY CONDITIONS FOR PIPES
6.1 Delivery
Early delivery shall be preferred.
6.2 Place of Delivery:
Places or pipe storages designated by the Employer.
6.3 Transport and Storage of Pipes
The Contractor shall supply all necessary equipment for loading, transportation to
the construction site or storage site and unloading.
All pipes shall be protected against adverse weather conditions (including the
sunlight) and fouling during transportation, storage and stringing. The fouled pipes shall be
cleaned before placement.
6.3.1 Loading and Unloading of Pipes
The responsibility for obtaining all necessary permits for the transportation of pipes
shall rest with the Contractor. Where possible, the Contractor shall ensure that the weight
limits on public roads are not exceeded. The Contractor shall be responsible for making good
any damages caused to these roads.
35
In order to protect the pipes and special parts against any damage, special precautions
shall be taken during loading and unloading, overlapping pipe limits shall be separated from
each other by intermediary layers placed between them and pipes shall be secured against
rolling, slippage, bending and vibration. During loading and unloading of the pipes with
external isolation, damaging of the isolation layer shall be definitely prevented by using wide
bands or similar arrangements. The isolated pipes shall not be transported when the ambient
temperature falls below -7o C.
Pipes shall be lifted up and put down with minimum damage as much as possible.
They shall be lifted by a sling made from a material that does not cause any damage to the
pipes and their coating. The Contractor shall visually examine the pipes in order to check for
the damages and, if there are any, shall inform the Control Engineer in respect thereof. The
Contractor shall be responsible for making good any damage or defect with the approval of
the Control Engineer.
Pipes shall be definitely protected against strikes (e.g., throwing the pipes to the
floor, rapid pull or drop of lifting bands, or dropping the pipes onto the floor or something
else).
6.3.2 Storage of pipes

Storage of pipes shall be such that soil, mud, water or other substances can not enter
the pipes. Pipe isolation layer shall never be in contact with the materials harmful to the
isolation. Support and stack height for the stored pipes shall be such that the pipes are
prevented from any damage and permanent deformation, and shall be determined so that
external isolation is protected. Pipes shall be stacked in such manner that the pipes will not
roll and will be clear of local contacts. Pipes shall not be stacked diagonally, and the contact
of the pipes with each other shall be uniform and along their whole length.
Since vegetable exiles irritate the bitumen-based external isolation, pipes shall never
be laid on the vegetable soil directly.
If storage of the pipes is inevitable at places where there is a risk of frost, the contact
of the pipes with the frozen ground shall be avoided and the pipes shall be protected from
sticking on the ground.
Isolated pipes shall be protected against sunlight by covering during hot seasons.
When pipes are collected from a storage site, the Contractor shall secure the remaining
pipes against slippage. When a storage site is emptied of materials, the Contractor shall clean
the site and any access road and reinstate both to their original condition.
The pipes shall be strung consecutively along their length on timbers or similar, with
at least two per pipe, to avoid damaging or fouling the pipes. The pipes shall be strung in such
a way that the normal use of the surrounding areas is disturbed as little as possible. Pipes shall
be secured against rolling. When stringing the pipes according to diameter tolerance symbols,
the “+” signed ends shall never touch the “-” signed ends.
The Contractor shall be responsible for the transportation, loading, unloading,

stacking, and storing of the pipes and supplying all the necessary tools and workers. The
Contractor shall take all safety precautions during loading, unloading and transportation of the
pipes. Any damaged part of coating shall be broken, cleaned and remade. The pipes shall be
36
supported by reinforcement elements during transportation, the Contractor shall take
precautions to secure them against slippage or bending, and the pipes shall be bedded
accordingly to protect coatings against any damage. All these operations shall be in
accordance with TS 2170.
7 GENERAL CHARACTERISTICS
1. Companies shall indicate in their offers the welding method they propose, and they
shall perform welding in accordance with the specifications.
2. Companies shall not include the expenses concerning the tests in the material cost and
shall indicate them as a separate item. However, the “Employer” shall assume no
liability for such cost.
3. The tests required at each phase from manufacturing of the pipe until delivery shall be
made under the supervision of the Employer, at a laboratory designated by the
Employer, or a laboratory designated by the supplier, and the test results shall be
submitted to the Employer in a report. Tests shall be made at three steps as described
below:
- Step 1: Once the spiral-welded steel pipe is manufactured, the tests to be made
on the plain pipes before coating.
- Step 2: The tests to be made after external coating of the pipe.
- Step 3: The tests to be made after internal coating of the pipe.
4. Companies shall indicate in their offers the type of curing to be applied to internal
coating.
5. The rules specified in the specifications regarding the protection and transportation of
the pipes shall be followed.
6. The Company shall provide accommodation, travel and boarding services for the
committee to be set up by the Employer for conduction of all the necessary test(s)
during manufacturing.
7. DIN 100 and DIN 150 steel pipes shall be manufactured with ERW (longitudinal
electric resistance) and larger diameter pipes with SAW (spiral submerged) welding.
37
8 DIMENSIONS AND QUANTITY OF STEEL PIPES TO BE SUPPLIED
PIPE WALL EXTERNAL INTERNA PİPE QUANTITY

DIAMETER THICKNESS COATING L COATING LENGTH
(NOMINAL
DIAMETER)
6m
6m
9 INSPECTION
9.1 Visual inspection
Visual inspection of both inside and outside of the pipes shall be carried out.
9.2 Dimensional Inspection
Dimensional inspection of all pipes shall be carried out for compliance purposes.
9.3 Pipe Isolation Test
Isolation layer shall be tested in accordance with the DIN 19630 or equivalent.
9.4 Production Tests
The Control Engineer shall be entitled to select a set of weld seams for destructive
tests.
The responsibility for cutting and removal of the weld seams, opening of the pipe
ends and rewelding of the joints shall rest with the Employer.
Unless otherwise agreed upon, the destructive tests shall be in accordance with the
requirements of the related general welding specifications, which includes the sufficiency
tests of the welding methods.
If it is proved that the welds are of the required quality, the cost of tests shall be born
by the Employer. If it is found out that the welds are not in compliance with the requirements,
38
the cost of tests shall be born by the Contractor. In this case, the Control Engineer may insist
on testing of a second weld, whatever the result of this second test, the cost of test and of
replacement shall be born by the Contractor. If the second weld is not in compliance with the
requirements, the inspections may be expanded at the Contractor’s expense.
The Control Engineer shall determine the scope of the additional inspections to
ensure better understanding of the compliance of the welding with the relevant requirements.
A change in personnel during welding may have effect on the quality of the weld
seams. When this is the case, the Control Engineer may request the destructive test of a new
welding at the Contractor’s expense.
9.5 Factory Made Bends
Changes of direction or inclination which cannot be made either with elastic bend or
field bends shall be made with factory-made bends supplied by the Contractor.
Factory-made bends shall be made with R = 1.5 x D or 3 x D . When factory-made

bends which are cut in the field, the portion not immediately required shall be marked with its
new angle.
9.6 Tees and Y’s
Tees, crosses, branches, Y’s, manifolds, or other fittings that provide means of
dividing or uniting flow in pipelines shall be either factory-made or manufactured at the site.
Appropriate reinforcement threads and securing elements shall be provided for the Tees to be
manufactured.
Tees and Y’s shall be reinforced by wrappings or collars as shown on the drawings.
The wrappings and collars shall be designed using the method described in the ASME
Pressurized Vessels Not Contacting with Flame, Section VIII. Design shall, in any case, be
submitted to the Control Engineer for approval.
9.7 Steel Pipes with Rubber Gasket Spigots
9.7.1 Manufacturing of Steel Pipes with Rubber Gasket Spigots
Manufacturing of the pipes with spigot shall be in accordance with the standards
including AWWA C 200, DIN 2614, DIN 2460, NFA 49-150, and UNI 6363.
The spigot ends shall be manufactured by pressing without hammering, or rolling, or

from separate plate or sheet or special parts for jointing the pipe. The flat ends shall be
manufactured and shaped as shown in order to hold the gasket. Flat and spiral seams in the
spigot or on the outside of flat end shall be grinded up to pipe surface in a distance not less
39
than that of the flat end section that enters the spigot. The manufacturer shall provide the
drawings of the additional details to the approval by the customer.
Different types are available from several manufacturers. The joints shall be
enclosed by jointless plastic ring gaskets supplied by the manufacturer. The gasket shall
contact with the spigot and flat end of the pipe with a sufficient pressure in order to maintain
sealing under any allowable jointing conditions and shall have a cross section size.
The gasket shall be the only element that provides sealing of the joint and shall have
a smooth surface free from dents, blisters, pores and other defects.
Composition of the gasket shall consist of first class natural crude rubber or first
class synthetic rubber in an amount not less than 50%. The remaining portion of the
composition shall consist of filler not containing scrap rubber, materials harmful to health, or
substitute materials for elastic rubber.
When tested according to the relevant standard, the composition shall have a tensile
strength and ultimate extension within the acceptable limits.
9.7.2 Joints of Steel Pipes with Rubber Gasket Spigot
The flat end of the pipe shall be placed so that its rubber spigot end contacts with
sufficient pressure. Before welding, the pipe axes shall be coincided using a centering
mechanism. Both the spigot end and the flat end shall be cleaned, and the spigot end shall be
welded to the other end using the cross-section provided by the manufacturer. After that,
bitumen or epoxy paste shall be applied to the pipe ring between the rubber gasket and the flat
end. These processes shall be in accordance with the welding and welding workmanship
specifications.
9.8 Coating of Weld Seams
After successful completion of all the inspections, the weld seams and the
surrounding zone shall be carefully cleaned, and protected by internal and external coating as
stated in the specification.
10 MARKING
The name of the “Employer”
Manufacturer’s emblem or descriptive mark
Symbol of the part’s name (A, F, FR, K, etc.)
Diameter of the part
11 PACKAGING
40
All connecting pieces shall be packaged and shipped in wooden crates.
Packing crates shall be strong enough to allow the transportation of the materials
without breaking.
Packing crates shall be enclosed by steel strips on four sides.
Crate bottoms shall be reinforced on both sides with wooden battens having a
dimension of 12 x 12 (in order to provide loading and strength).
12 CONTENT OF OFFER
The Contractor shall state in its offer the quantities, unit prices and total prices of the
parts, together with the symbols shown in the list attached hereto.
The quantities of the necessary gaskets shall be stated separately, clearly indicating
their unit and total prices.
If gaskets, bolts and nuts are to be offered free of charge, this should be indicated in
the offer.
Calculated gaskets shall be supplied free of charge in excess of 20%.
For all technical issues incorporated in this technical specifications, the offered pipe
and its parts as well as its coatings, gaskets, bolts and nuts shall be indicated separately and
their detailed technical values shall be provided in tables.
The Contractor shall, at the time of submission of offers, give to the Employer for
examination a sample pipe connecting piece having the characteristics stated in the offer.
13 ACCEPTANCE - CONDITIONAL ACCEPTANCE - REJECTION
13.1 Acceptance
The lot represented by the sample and test pieces, which appear to be compatible with
all the requirements at the end of the inspections and tests made on the test pieces that
represent the condition corresponding to the samples taken from the lot delivered, shall be
accepted.
13.2 Conditional Acceptance
If 2% of the samples that have been taken for the inspections mentioned above are
found out to be defective, however, if this does not lead to non-use of the material, the
conditional acceptance of the lot shall be made.
No payment shall be made for the parts found defective and returned at the end of the
inspection of the lot.
41
13.3 Rejection
The lot shall be rejected if the samples and/or the test pieces representing the condition
corresponding to the samples are found to be incompatible with the required characteristics
and tolerances at the end of the aforementioned tests.
14 DELIVERY
As described above, the pipes shall be delivered to the Employer as packaged and
marked.
Pipe connecting pieces shall be delivered as packaged, with the gaskets placed on
them.
Gaskets may be delivered in a separate package since they will be proposed in excess
of 20%.
Bolts and nuts shall be separately packaged and delivered.
15 ORDER FORM
An order form for the pipes and parts demanded is given in the Annex.
16 TECHNICAL INSPECTION
The Contractor shall invite the Employer’s technical committee consisting of 2

members for technical inspection of the manufacturing progress for a duration of 1 week. All
the accommodation and travel expenses in respect thereof shall be at the Contractor’s
expense.
17 TRANSPORT AND STORAGE
Pipes shall be supported by timbers not only at the bottom row and between rows but
also from their sides, ends and top in order to prevent any accidental damage during
transportation.
Utmost care shall be taken during the transportation of the asbestos cement pipes, and
the pipes shall not be unloaded, loaded and stacked by throwing, rolling and dragging. The
transportation shall involve minimum loading/unloading operations. The pipes shall be always
lifted by hand and using rope, wooden beams, or lifting mechanisms or machines.
42
HDPE 100 (HIGH DENSITY POLYETHYLEN) PIPES
1 SUBJECT AND SCOPE
This specifications describes the technical specifications, control and inspection

methods as well as acceptance criteria for the production of High Density Polyethylene
(HDPE) pipe and its connecting pieces. These pipes shall be used for the water supply
pipeline and for irrigation purposes by the General Directorate of State Hydraulic Works
(Employer).
HDPE 100 pipes shall be manufactured and tested according to the requirements of
this Specifications and its annexes, and specifically to the TSE, DIN, ASTM and AWWA
standards of relevance to the subject matter, or their equivalents acceptable to the Employer,
whether or not their numbers are shown in this Specifications or its annexes.
The pipes shall be used at the places where high pressure is needed for the distribution
of irrigation water and drinking water.
2 GENERAL
HDPE 100 pipes are generally used for distribution of pressurized clean water and
irrigation water. They can achieve the pressure values resisted by the pipe at the same
diameter produced from PE with smaller wall thickness.
Chemical analysis shall be conducted by sending the samples selected from the
produced pipes to the Technical Research and Quality Control Department (TRQCD) or to a
laboratory approved by it.
The suppliers that have laboratories with sufficient equipment and regularly calibrated
shall be preferred.
HDPE 100 pipes should have ISO 9000 quality assurance system and should be
certified.
Production standard, nominal diameter, wall thickness, norm numbers, and the
manufacturer’s name shall be written on the pipes.
2.2 Pipe Characteristics
2.2.1 Physical Characteristics
The physical characteristics of the HDPE 100 drinking water pipes are as follows:
 They are resistant to impacts (outer pressure, strokes). Since it is able to extend by 6
times of its length is flexible and resistant to the ground movements.
43
 They are resistant to ram impact pressure
 When pipes are filled with water and without use of any valves it is possible to repair
with the suffocate method.
 When pipes are filled with water it is possible to make service water connections by
use of special branch separator without cutting the water
 Since there is no rupture, fracture, etc. there is not any damage due to transportation,
loading, unloading and mounting.
 Their inner surfaces are smooth and frictional losses are at minimum. For this reason
the project design diameter can be minimized.
 They can stretch and bend easily and they do not break. For this reason, roll can be
made.
 They contribute to heat insulation during transportation of hot and cold fluids,
provides energy savings.
2.2.2 Chemical Characteristics
The chemical characteristics of the HDPE 100 drinking water pipes are as follows:
 They maintain their standard characteristics even they are stored at the open air thanks
to the high UV resistance
 They have high resistance to soil alkaline metals. They do not react with these types
and do not decay.
 They have high chemical resistance.
 They do not effected by the moisture when under the ground. They are resistant to
corrosion and pressure.
 They are hygienic
2.3 Standards
HDPE 100 pipes shall be in accordance with TSE 2490, 2491, 2492, 2494 and 2494.
2.4 Raw Materials
HDPE 100 pipes are produced from high density polyethylene raw material which is
also named as linear polyethylene. High density polyethylene includes 90% crystal structure
in its composition and have at least 200 carbon atoms.
Specific gravity of the high density polyethylene defined as Type III and Type IV
according to the ASTM Standards is 0.940 gr/cm3 or higher. HDPE provides 33% raw
material saving when compared with PE.
The supplier shall submit to the Employer all information and documents regarding
the source of the raw material and all the characteristics.
The raw material used in HDPE 100 pipe production shall be provided from member
producers of “PE 100 Association”, and this condition shall be proved with certificates and
44
documents. “PE 100 Association” is an association who is responsible of maintaining the
quality of PE 100 by controlling the suppliers who produce PE 100 at a certain quality semi-
annually, terminating the membership of the companies who are not sustainable in quality and
continuously updating the member list.
2.5 Technical Characteristics
Technical characteristics of the HDPE pipes are as follows :
 There is no rupture or separation at the connections; definite impermeability.

 They can be connected out of the channel.
 Chemical resistance of the pipe material is high, does not affected from corrosion,
does not decay or wear out.
 The need for less filling material transported from outside, less excavation.
 Can be easily used at sea, streams, rivers, defected grounds and places where ground
movement is possible like mines.
 Inner surface is hydraulically smooth. The pipe diameter in the project can be
minimized, the energy utilization during operation is at minimum. It generally reduces
the operational costs.
 Since they are able to rotate with a radius 20-35 times of the pipe diameter, need of
bends is minimum.
 Strength (laying and transporting without loss)
 The production plants can be mobilized, and significant savings can be achieved in
main projects by on Site production.
 The minimum life is 50 years and operational cost are very low without need for
maintenance.
 During laying there is no need for concrete masses for places like bend and T parts.
 They are light weight and easily and quickly laid. This is advantageous for places with
short construction season and high traffic.
 Flexible
 High fracture strength and impact strength
 Adapts to the shape of the land
 Do not affected from the sun light thanks to the carbon black in its structure (UV
strength)
 Diversity in pressure strength (can be produced for 12 different pressure class from PN
2, 5 to PN 32)
 Since they are not affected form the cathodic materials under the ground they do not
require protection systems like cathodic protection.
 The density of the material shall not be less than 950  10 kg/m3 when measured in
accordance with ISO 1183 D/ ISO 1872 - 2B test method.
 The solution flow rate shall be between 3 - 0,7 gr/10 minutes when measured in
accordance with ISO 1133 test method less than 190 C temperature and 5 kg load.
 The extension at the rupture moment shall not be less than 350% according to the ISO
6259 test method,
 The longitudinal expansion coefficient shall be approximately 0,2 mm/m C when
determined in accordance with ISO 6259 test method at temperature between 20 C and
90 C
 The product, pipe and connecting pieces from HDPE shall be in accordance with DIN
8074 – DIN 8075 standards.
45
2.6 Pipe Jointing Methods
The same jointing methods with that of the PE pipes shall be used for the HDPE.
2.7 Wear Resistance
The most resistant material to fluid particles are the pipes produced from HDPE 100.
At first, 100.000 test cycles conducted for inner surface of the pipe produced from the
HDPE 100 material the wearing out result is only 0.09 mm.
2.8 Nominal Pressure
Nominal pressure is the maximum working pressure level that can be used by the
HDPE 100 pipe, calculated by the Employer with the parameters of 50 years of service life
and 20 C operational temperature.
Polyethylene classification according to EN 12201, the draft version of CEN 155.
The relations between PN, S and SDR values of MRS class material at 20 C.
PN ( Bar)
Material Class
SDR S PE 32 PE 40 PE 63 PE 80 PE 100
41 20 - - 2.5 3.2 4
33 16 - - 3.2 4 5
27.6 13.3 - - - - 6
26 12.5 - 2.5 4 5 -
22 10.5 - - - 6 -
21 10 2.5 3.2 5 - 8
17.6 8.3 - - 6 - -
17 8 3.2 4 - 8 10
13.6 6.3 4 5 8 10 12.5
11.6 5.3 - 6 - - -
11 5 5 - 10 12.5 16
9.4 4.2 6 - - - -
9 4 - 8 12.5 16 20
7.4 3.2 8 10 16 20 25
6 2.5 10 12.5 20 25 32
46
2.9 Special Conditions
 The raw material shall be with Carbon Black additive and shall be in the granular form
ready for extrusion in order to increase the UV resistance.
 The manufacturer shall give all the characteristics of the raw material.
 The raw material shall be provided from raw material company, withstanding -40 C
temperature in rigids.
 The resistance of the pipe and connecting pieces to chemicals shall be submitted
together with the raw material characteristics by the manufacturer.
3 INSPECTION AND TESTS
 The test and cross sections of the pipes and connecting pieces shall be in accordance
with DIN standards.
The environmental tensile strength of the HDPE pipes due to internal pressure effect
shall be in accordance with ISO /DIS 4427 standards.
 If it is considered as necessary by the Tendering committee, the test and tests
specified in the standards shall be conducted for pipes and connecting pieces at the
manufacturer’s expense.
 The factory test pressure shall be in accordance with DIN 8075
4 DIMENSIONS AND TOLERANCES
 The manufacturer shall provide the technical pictures and all sizes of the manufactured
pipes and connecting pieces for each diameter and pressure.
 The pipes shall be 12 m in length or close degree.
 The sizes and tolerances of the pipes and the connecting pieces shall be in accordance
with DIN 16963.
 The manufacturers shall make commitment for owning production technology for
each diameter and connection piece related to the project.
5 JOINTING
The connections shall be in accordance with one of the following methods

acceptable to the Employer.
a- Butt welding
b- Fillet welding for both sides
c- Fillet welding for one side
d- Electro-fusion welding
47
6 LAYING DESIGN
The manufacturers shall guarantee the smooth operation of the pipe by submitting
suitable burying design according to the soil load and traffic load that can effect the pipe
within this project.
7 MARKING
The name and logo of the “Employer” shall be written on the pipes.
8 TRANSPORT AND STORAGE OF PIPES
The Contractor shall supply all necessary equipment for loading, transportation to
the construction site or storage site and unloading.
All pipes shall be protected against adverse weather conditions (including the
sunlight) and fouling during transportation, storage and stringing. The fouled pipes shall be
cleaned before placement.
8.1 Loading and unloading of pipes
The responsibility for obtaining all necessary permits for the transportation of pipes
shall rest with the Contractor. Where possible, the Contractor shall ensure that the weight
limits on public roads are not exceeded. The Contractor shall be responsible for making good
any damages caused to these roads.
In order to protect the pipes and special parts against any damage, special precautions
shall be taken during loading and unloading, overlapping pipe limits shall be separated from
each other by intermediary layers placed between them and pipes shall be secured against
rolling, slippage, bending and vibration. During loading and unloading of the pipes with
external isolation, the pipes with damaged isolation layer due to use of wide bands or similar
arrangements shall definitely not be used. The isolated pipes shall not be transported when the
ambient temperature falls below -7o C.
Pipes shall be lifted up and put down with minimum damage as much as possible.
They shall be lifted by a sling made from a material that does not cause any damage to the
pipes and their coating. The Contractor shall visually examine the pipes in order to check for
the damages and, if there are any, shall inform the Control Engineer in respect thereof. The
Contractor shall be responsible for making good any damage or defect with the approval of
the Control Engineer.
Pipes shall be definitely protected against strikes (e.g., throwing the pipes to the
floor, rapid pull or drop of lifting bands, or dropping the pipes onto the floor or something
else).
48
8.2 Storage of pipes
Storage of pipes shall be such that soil, mud, water or other substances can not enter
the pipes. Pipe isolation layer shall never be in contact with the materials harmful to the
isolation. Support and stack height for the stored pipes shall be such that the pipes are
prevented from any damage and permanent deformation, and shall be determined so that
external isolation is protected. Pipes shall be stacked in such manner that the pipes will not
roll and will be clear of local contacts. Pipes shall not be stacked diagonally, and the contact
of the pipes with each other shall be uniform and along their whole length.
Since vegetable exiles irritate the bitumen-based external isolation, pipes shall never
be laid on the vegetable soil directly.
If storage of the pipes is inevitable at places where there is a risk of frost, the contact
of the pipes with the frozen ground shall be avoided and the pipes shall be protected from
sticking on the ground.
Isolated pipes shall be protected against sunlight by covering during hot seasons.
When pipes are collected from a storage site, the Contractor shall secure the remaining
pipes against slippage. When a storage site is emptied of materials, the Contractor shall clean
the site and any access road and reinstate both to their original condition.
The pipes shall be strung consecutively along their length on timbers or similar, with
at least two per pipe, to avoid damaging or fouling the pipes. The pipes shall be strung in such
a way that the normal use of the surrounding areas is disturbed as little as possible. Pipes shall
be secured against rolling. When stringing the pipes according to diameter tolerance symbols,
the “+” signed ends shall never touch the “-” signed ends.
The Contractor shall be responsible for the transportation, loading, unloading,

stacking, and storing of the pipes and supplying all the necessary tools and workers. The
Contractor shall take all safety precautions during loading, unloading and transportation of the
pipes. Any damaged part of coating shall be broken, cleaned and remade. The pipes shall be
supported by reinforcement elements during transportation, the Contractor shall take
precautions to secure them against slippage or bending, and the pipes shall be bedded
accordingly to protect coatings against any damage. All these operations shall be in
accordance with TS 2170.
9 GENERAL CHARACTERISTICS
Companies shall indicate in their offers the welding method they propose, and they
shall perform welding in accordance with the specifications.
Companies shall not include the expenses concerning the tests in the material cost and
shall indicate them as a separate item. However, the “Employer” shall assume no liability for
such cost.
The tests required at each phase from manufacturing of the pipe until delivery shall be
made under the supervision of the Employer, at a laboratory designated by the Employer, or a
laboratory designated by the supplier, and the test results shall be submitted to the Employer
49
in a report. The rules specified in the specifications regarding the protection and
transportation of the pipes shall be followed.
Companies shall provide accommodation, travel and boarding services for the
committee to be set up by the Employer for conduction of all the necessary test(s) during
manufacturing.
10 DIMENSIONS AND QUANTITY OF STEEL PIPES TO BE SUPPLIED
PIPE WALL EXTERNAL INTERNAL PIPE QUANTITY

DIAMETER THICKNESS COATING COATING LENGTH
(NOMINAL
DIAMETER)
6m
6m
11 GENERAL DELIVERY CONDITIONS FOR PIPES
11.1 Delivery
Delivery place: Place Places or pipe storages designated by the Employer.
Early delivery shall be preferred.
50
GLASS REINFORCED PLASTIC (GRP) PIPES
1 GENERAL
This Specifications gives the descriptions, classification, technical specifications,

inspection and test methods as well as acceptance criteria for the glass reinforced plastic
(GRP) pipes produced by combining glass fiber reinforced material, thermostat resin, sand,
calcium carbonate and other chemical additive materials as composite material.
GRP pipes to be used for the water supply pipeline and for water system shall be in
accordance with the requirements of this Specifications and its annexes, and with AWWA C
950-88, AWWA M-45, ASTM D 3262, ASTM D 3517, ASTM D 3754, ASTM D 4162, DIN
16869, BS 5480 and TS 4355 or equivalent acceptable to the Employer.
In case of any difference between the standards and the requirements of this
Specifications, the Employer shall be free to decide on which will prevail.
Document and catalog demonstrating the conformity with the relevant standards shall
be submitted to the Control Engineer for approval.
2 DEFINITIONS
2.1 Glazing gasket
Glass reinforcement material formed by wrapping up parallel continuous glass fibers

coated by sizing and binder from E or ECR glass in order to form a bobbin (shall be in
accordance with ASTM D 3754 Clause 5.2.3).
2.2 Trimmed Glass Fiber
Glass reinforcement material formed by trimming and cutting the product glazing
gasket from E or ECR glass in 50-60 mm length to be used for reinforcement material (shall
be in accordance with ASTM D 3754 Clause 5.2.3)
2.3 Glass Texture
Reinforcement material formed by weaving the glazing gasket (leaving spaces

between them) to form a mat (shall be in accordance with ASTM D 3754 Clause 5.2.3)
51
2.4 Surface Tulle
A kind of material produced from glass fiber (30-50 gram per square meter) for
reinforcement of coating layers (when necessary) increasing the chemical strength at the
surfaces. (shall be in accordance with ASTM D 3754 Clause 5.2.3)
2.5 Coating Layer
A layer composed of completely pure resin whose purpose is to increase the chemical
strength applied at the surfaces of the glass fiber reinforced pipe and connecting pieces that
are in contact with the corrosive or fluid environment. (shall be in accordance with ASTM D
3754 Clause 5.2.3)
2.6 Resin
Thermosetting ortaphalic and/or hydropthalic polyester resin (shall be in accordance

with ASTM D 3754 Clause 5.2.1)
2.7 Glass Felt
A reinforcement layer formed by homogeneously distributing the glass fibers trimmed

to 60 mm pieces to form a surface and pressing with a suitable binder material.
2.8 Aggregate
Inert materials like calcium carbonate, silica sand that are used for increasing the
performance and/or decreasing the costs in the manufacturing of glass fiber reinforced pipe
connecting pieces. (Silica sand in compatible with ASTM D 3754 Clause 5.2.2)
2.9 Nominal Pressure
Maximum working pressure level of the glass reinforced plastic pipes calculated on
the basis of 50 years of service life by the producer.
2.10 Nominal Rigidness
The rigidness or stiffness value in the pipes is the peak load bearing strength
representing the strength against negative pressure (vacuum) and dynamic loads like traffic,
static loads like backfilling material and natural ground of the pipe.
ISO Standards recommends that the rigidness value of the pipes laid under the ground
shall be at least 2000 N/m2 in long term. Except for the grounds that are very strong and
52
durable and with no under ground water, the pipes whose rigidness value are less or equal to
2500 N/m2 shall never be used for buried applications.
3 CONNECTION TYPES
The pipe shall have a impermeable joint in order to provide the service conditions.
(shall be in accordance with ASTM D 3754 Clause 5.4).
3.1 Sleeve Joint
Joint formed by flexible connection of pipes in a flat end sleeve. It can be formed with
DC type sleeves where there are holes for elastomeric gaskets at both sides and middle of the
joint sleeve in order to provide impermeability; or it can be formed by FWC type sleeve
whose inner surface is completely coated with elastomer E.P.D.M. (ethyl propylene) at 55 + 5
shore A hardness.
3.2 Gasket Spigot Joint
It is a flexible joint formed by inserting the flat end of the pipe through the spigot end
of the other pipe by using a gasket. The hole for placing elastomeric gaskets can be at the
spigot part or on the flat pipe end.
3.3 Hand lay-up connection
Joint formed by jointing the ends of both pipes and coating the jointing place with
glass reinforcement material and polyester resin at sufficient width and thickness for
providing adequate connection strength.
3.4 Flanged Joint
Joint formed by placing face to face the flanges that are jointed to the pipes by hand
lay-up and manufactured from Glass Reinforced Plastic, and connecting them with bolts, nuts
and gaskets.
4 CLASSIFICATION
4.1 Classification by Pressure Classes
Glass reinforced plastic pipes are classified in five nominal pressure groups as a
standard.
53
Gravity
PN 6 Atm.
PN 10 Atm.
PN 16 Atm.
PN 25 Atm.
However, for project purposes they can be produced for ungraded different nominal
pressures from gravity to 35 atm.
4.2 Classification by Rigidness Classes
Glass fiber reinforced plastic pipes are classified in three different rigidness class as
shown in Table 1 as standard.
Table 1 – CTP Pipe Rigidness Values

Normal Rigidness Group I Group II Group III
SN: N/m2 (ISO) SN 2500 SN 5000 SN 10000
SR:N/mm2(DIN,ATV 0.02 0.04 0.08
)
F/dv: Psi (ASTM) 18 36 72
However, CTP pipes can be produced for different rigidness classes according to the
project requirements.
5 MANUFACTURING
Glass reinforced plastic pipes can be manufactured by centrifugal casting method

where materials are introduced into a rotating mold for compaction or can be manufactured by
fiber wrapping method.
5.1 Fiber Wrapping Method
Pipes produced by fiber wrapping method consist of three main layers:
5.1.1 Internal Surface Layer
It shall produce a resin rich layer minimum 0.5 mm in thickness in the internal surface
of the pipe.
5.1.2 Strength Layers
There are strength layers according to the design of its manufacturer in this layer.
54
5.1.3 External Surface Layer
It shall produce a resin rich layer minimum 0.2 mm in thickness on the external
surface of the pipe.
5.2 Centrifugal Casting Method
Pipes produced by centrifugal casting method are consist of from four layers.
5.2.1 External Surface Layer
A resin rich layer minimum 0.2 mm in thickness mixed with sand at the external
surface of the pipe, protects the pipe from ultra-violet light and impacts.
5.2.2 Strength Layers
There are 10 strength layers designed according to operational conditions of the pipe
at this section.
5.2.3 Barrier Layer
On the primer layer, 2.0-2.5 mm in thickness, consist of 2 separate layers, resin rich,
reinforced with fiberglass 10-40% by weight, barrier layer for preventing the leakages.
5.2.4 Primer layer

At the innermost layer of the pipe, pure resin layer 1.0-2.5 mm in thickness (Standards
prohibits the fiberglass in this layer). Since this layer is compacted by approximately 60 bar of
centrifugal force it is as smooth as glass (in 1/100 mm precision).
6 TECHNICAL SPECIFICATIONS
6.1 Length
Glass Reinforced Plastic Pipes shall be produced according to sizes and tolerances
given in the ASTM D 3754 Clause 6.2.1.
6.2 Surface Quality
There shall be no foreign substances, wrinkles and cracks on the I surfaces of the
pipes. For each m2of I surface there shall not be holes more than 20 and 3.2 mm in diameter
55
and there shall not be any glass fibers not weaved by resin. (shall be in accordance with
ASTM D 3754 Clause 6.1 )
6.3 Nominal Diameters
Glass reinforced plastic pipes shall be produced according to nominal diameters and
tolerances specified in ASTM D 3754 Article 6.2.1.
6.4 Wall Thickness
U uniformity of the Glass Reinforced Plastic concrete shall be in accordance with

ASTM D 3754 Article 6.2.4.
6.5 Flatness of Pipe Ends
Regularity of the Glass Reinforced Plastic Concrete shall be in accordance with

tolerances suitable to ASTM D 3754 Article 6.2.4.
Pipe ends shall be perpendicular to pipe axis. Deviation of pipe ends from the plane
perpendicular to pipe axis shall be smaller than “2 mm + 0.005 x D”. (D represents nominal
diameter given in mm)
6.6 Impermeability
All GRP pipes and joint sleeves (one by one) shall be subjected to impermeability
tests under pressure values given in Table 2 at the factory and existence of leakages and
defects shall be controlled. (shall be in accordance with ASTM D 3754 Clause 6.4)
6.7 Nominal Diameters
Glass reinforced plastic pipes shall be produced in accordance with the nominal
diameters and tolerances specified in ASTM D 3754 Article 6.2.1.
Pipe useful length shall not be different from pipe nominal length more than + 5%.
6.8 Inside diameter
The measured pipe inside diameter shall not be different from the specified inside
diameter values more than + 2%.
56
7 INSPECTION AND ACCEPTANCE CRITERIA
The GRP pipes shall be manufactured and marked in accordance with the
requirements given in the specification. The surface appearance of the glass fiber reinforced
pipes shall be in accordance with the specification.
For pipe tests each 50 pipes with the same diameter are considered as one party. A
sample is taken from each lot. From this sample pipe:
A sample for rigidness test

3 samples for circumferential tensile strength test
3 samples for longitudinal tensile strength
Circumferential tensile strength and longitudinal tensile strength results are calculated
by taking averages of the test results. If the required values are provided according to the test
results the lot shall be accepted. Otherwise, a new sample pipe is taken, for negative results
due to that sample, necessary number of samples are taken again and the lot is accepted
provided that the new samples give positive result. If the results are negative the lot is
rejected.
7.1 Impermeability Test
For pipes manufactured by fiber wrapping method the impermeability test shall be
applied for all the pipes (one by one).
The impermeability test shall be performed in accordance with TS 4355 Article 2.3.2,
the fiberglass reinforced pipes are placed in the hydrostatic presser test device such that there
will be no force in the axial direction. After that, they are filled with water and air is
discharged. The internal pressure is increased with a rate not more than 1 Atmosphere per
second until it reaches to a value given in Table 2. It is then waited for 3 minutes at this
condition. There shall be no dripping, leakage or defect on the pipe.
For pipes manufactured by centrifugal casting method, it can also be performed, in

addition to this it can be performed by blow up method. In the blow up test, the pipes and
sleeves with the same diameter and nominal pressure are considered as one party, the 2% of
the pipes are tested under pressure equal to the 4 times of nominal pressure value given in
Table 4. The sample size is 1000 mm for all the diameters with sleeves at both ends.
Table 2 – Factory Test Pressure Values of the GRP Pipes

Pressure Class (Atm.) Impermeability Test Pressure (Atm.)
6 12
10 20
16 32
25 40
There shall be no dripping, leakage and defect on the pipe.
57
7.2 Circular Tensile Strength Test
The results found after circular tensile strength test performed in accordance with the
related standards shall be compatible with the TS 4355 Clause 1.2.5.3.
7.3 Longitudinal Tensile Strength Test
The results found after longitudinal tensile strength test performed in accordance with
the related standards shall be compatible with the TS 4355 Clause 1.2.5.3.
7.4 Rigidness Tests
The values found after performing rigidness tests according to the related standards
shall be compatible with Table 1 and 3.
Table 3 – Deflection without any defect or structural damage

Deflection Level Rigidness Class
SN 2500 SN 5000 SN 10000
At Level A under load for 6 min. 15% 12% 9%
At Level A under load for 6 min. 25% 20% 15%
At Level D under load for 24 hours 20% 16% 12%
A: There shall be no trace of defect on the pipe.

B: There shall be no segregation among laminates, no separation of fibers
D: Deflection without fracture or leakage (flexibility)
7.5 Factory Product Control Tests
During manufacturing of fiberglass reinforced plastic pipes the following tests shall be
performed periodically at the required frequency:
Impermeability tests shall be performed in accordance with Clause 7.1

Circular tensile strength test shall be performed at least once at every work shift
Longitudinal Tensile strength test shall be performed at least once at every work shift
Rigidness tests shall be applied at least once at every work shift
Surface hardness tests shall be performed at least once at every work shift. When
surface hardness is tested in accordance with TS 4355 Clause : 2.3.1 the result shall be
minimum 40 Barcol hardness.
58
8 GENERAL DELIVERY CONDITIONS FOR GRP PIPES
8.1 Marking of Pipes and Special Parts
The Manufacturer shall write the following information with a permanent paint on
each pipe, sleeve and special part:
Nominal diameter (DN)

Nominal pressure (PN)
Nominal Rigidness (SN)
Production Date
Production Number
Length
A sign indication the quality control check
Manufacturer logo and/or brand *
* Only for the pipes.
8.2 Surface Appearance of GRP Pipes
Pipe surfaces shall be free of the following:
Glass fibers not dampened with resin hanging out from the pipe or loosely connected
to the pipe on the surface of glass fiber reinforced plastic pipe.
Deposits of sand or resin.
Not dampened glass fibers
Pipe surfaces shall be free of the following, too:
Segregations as layer on GRP pipe wall

Cracks generally in star form due to impacts
Holes more than 10 and bigger than 1.5 mm in diameter per square meter of internal
surface. (shall be in accordance with ASTM D 3754 Article 6.1)
9 DESIGNING OF GRP PIPES AND SPECIAL PARTS
9.1 Hydraulic
International designing of fiberglass reinforced plastic pipes shall be in accordance

with the books:
a ) AWWA M-45 “Glass Reinforced Plastic Pipe Design Manual”

b ) ATV – A 127 “Guideline for Static Calculations of Drain Canals and Lines”
Hydraulic load loss calculations are made by using Hazen-Willams, Manning, Chezy,
Darcy-Weisbach and Colebrook-White formulas.
59
Additional load losses in the fiberglass reinforced plastic pipes, valves, bends and
special parts shall be taken into consideration.
Pw = Working pressure
Pc = GRP Pipe Nominal Pressure
The equation Pc > Pw shall be provided, in other words GRP Pipe Nominal Pressure
shall be greater than or equal to Working Pressure.
Necessary precautions shall be taken in order to ensure that the permissible impact
pressure on the pipeline is not exceeded.
Pc > (Pw + Ps) / 1.4 , Ps = Water impact pressure,
The sum of working pressure and water impact pressure shall be less than or equal to
the 1.4 times nominal pressure
9.2 Rigidness Class
Rigidness class of the GRP pipes are determined in accordance with AWWA M-45
Hand Book Section : 5 and/or ISO TR 10465 “Under Ground Laying Of Fiberglass
Reinforced, Thermosetting Resin (GRP) Flexible Pipes” book Section: 1,2 and 3 by
considering filler height, filler type in the pipe zone, natural ground type, traffic loads and
underground water level criterion.
In order to simplify the selection of rigidness class natural ground is divided into four
main groups as given in the Table 4.
Table 4 – Classification of Ground Groups, ISO/TR 10465-1

Definition Ground Group
I II III IV
GRANULES HIGH MEDIUM
(coarse grained) DENSITY Light silica or
fine matter And dense clay gravel or LOOSE VERY LOOSE
content is less stable grounds sand
than 5%
COHESION HARD STIFF MEDIUM SOFT
Fluid limit is With cohesion And very loose
(fine grained) With very stiff less than 50% and/or loose
cohesion grain
According to ground groups and trench depths the minimum pipe rigidness (SN) and
laying types are given in Table 5.
60
Table 5– Relationship Between Pipe Rigidness and Laying Types and Trench Depths–ISO/TR
10465-1
Trench Rigidness Natural Ground
Depth Class I II III IV
(m) SN ( N / m2 )
1250
Special 2500
Laying < 3 5000
10000
1250
Special 2500
Laying > 3 5000
10000
When determining the rigidness class, it is very important to determine the natural
ground characteristics and variations throughout the pipeline. In case there is an ambiguity on
this information, improving the laying process or increasing the rigidness class shall be
considered.
Since GRP files fall into flexible and semi-flexible pipe category, the external loads
shall be born by the pipe or the ground. For that reason, the quality and compaction of the
pipe zone, filler material has great importance.
The necessity of compaction of backfilling material comes from; bending, reshaping

(tensile) of GRP pipes with low rigidness is higher than the bending, reshaping of GRP pipes
with high rigidness.
For GRP pipes, compaction of pipe zone back filling material is forbidden according
to ISO TC 138/SC 6 SN 1250 (against the possible damaging of pipe). A light compaction can
be allowed for only SN 2500. As it is given in the tables given above, the pipe with rigidness
class SN 2500 can be used at very hard and tight grounds. Even for this natural ground case,
in order to prevent permanent deformation on the pipes the quality of the backfilling material
and ground compaction operations shall be carefully controlled.
The sudden “negative pressure” due to wrong operation of automatic

ventilation/discharge valves causes shrinkage at the pipes. 1 (one) bar of negative pressure
requires 4166 N/m2 rigidness. Consequently, for pipelines where there is a possibility of
formation of vacuum or negative pressure or Group III (most of the grounds fall in this class
in Turkey) natural ground conditions, pipes with SN 5000 rigidness class shall be used.
Pipes with SN 10000 rigidness class shall be preferred for ground with high under
ground water and grounds that are not capable of holding itself, where filler material of the
required quality is not available, use of compactor is not appropriate and in cases of fast
laying.
61
10 WATER SUPPLY PIPELINE EQUIPMENT
10.1 Fittings
All types of fittings to be used for the water supply pipelines shall be provided and
mounted in accordance with its own special specifications and standards.
10.2 Entrance into Pipelines (Manholes)
Entrance points shall be provided with specific intervals in order to provide access to
the line throughout the water supply pipeline. Generally suction rooms shall be used for this
purpose. In addition to this, if distance between two suction rooms is more than 1 km,
manholes shall be provided in order to keep the distance between two access points less than
1 km.
All the blind flanges on the access points of the complete water supply pipeline shall
be equipped with an air discharge tap of 25 mm as a security precaution in order to control the
internal pressure before loosening the blind flange.
The manholes shall be projected in different types according to its location and this
projects shall be submitted to the Employer for approval.
All the valves and fittings used for connections and water supply pipeline, shall be
projected for meeting the environmental and operational conditions given in this
specifications. The valves and fittings shall be provided by considering the maximum working
pressure including the impact pressure.
10.3 Manhole Covers
Cast iron covers of heavy service type or another type recommended by the Employer
shall be provided for all rooms on the water supply pipeline. The covers shall be GRP or cast
iron and shall be in the size and type shown in the project. On the top surface of the cover;
manufacturer name, the equipment type under it and the name or logo of the Employer
responsible for operation of that equipment shall be written as casting.
11 PIPELINE CONSTRUCTION
11.1 General
The GRP pipes to be used at the water supply pipeline shall be laid and tested in
accordance with the requirements of this specifications and its annexes, and particularly the
related TSE, DIN, ÖNORM, BS, ASTM, AWWA or an equivalent standard applicable to the
Employer whether its number specified in this specifications and annexes or not.
62
If there is a difference between the various standards and the requirements of this
specifications, the Employer is free to select the principle to be applied.
The works to be done on the pipeline are: transportation, loading and unloading of the
pipes, excavation of pipe trenches and back filling, excavation and filling works due to laying
and connection of the pipes, construction of trade structures, supply and mounting of the
special parts, valves and equipment, the test of the completed pipelines whose head
connections are in accordance with specification and other contract documents, construction
of anchorage blocks at the required locations and other works necessary for operation of the
pipeline.
11.2 Application
Application shall be performed in accordance with the project specifications.
11.3 Excavation Works
Excavation works shall be in accordance with the “DSİ Excavation Works Technical
Specifications”.
Bearings with minimum 10 cm of height shall be constructed for pipes on the trench
ground according to the structure of the ground. Coarse grained sand, gravel or crushed sand
compatible with the values specified in Table 7 shall be used as bearing material.
Table 7 – Maximum grain size

Maximum gravel or crushed
DN ( mm ) stone grain size
< 600 13 mm
600 – 1600 19 mm
> 1600 25 mm
In case that the natural ground structure of the trench ground is weak the bearing height of the
trench ground shall be increased to a degree in order to provide enough support for the pipe in
longitudinal direction. In addition to that for places with weak natural ground structure wider
trenches can be required in order to provide sufficient leaning strength.
11.4 Trench Filling
Filling of trenches shall be in accordance with “Excavation and Filling Works Specification”.
63
Table 8 - Minimum Filling Height on Traffic Load (wheel) Pipe
Type of the Load kN kgf Meter
AASHTO H 20 (20) 72 7250 1.0
BS 153 HA (C9) 90 9000 1.5
ATV LKW 12 © 40 4000 1.0
ATV SLW 30 © 50 5000 1.0
ATV SLW 60 © 10 10000 1.5
Cooper E 80 Railway 3.0
11.5 Loading, Unloading and Storage of GRP Pipes
During loading and unloading of the GRP pipes rubber or cord ropes shall be used.
During lowering/unloading the pipe shall be lowered under control by attaching a control cord
at one end of the pipe. During loading and unloading chain or steel ropes shall never be used.
Carrying the pipes by passing a rope inside it shall not be permissible.
During transportation of the pipes they shall be stored on smooth surfaced timbers and
they shall be fixed with wedges, rubber or cord ropes in order to prevent sliding or falling
because of the shakes that can occur during transportation.
The maximum storage height shall be 2.5 meters during transportation at the vehicles.
The pipes shall be stored on a smooth base and smooth surface timbers. They shall be
fixed with wedges, rubber or cord ropes in order to prevent sliding or falling. The maximum
storing height shall be 3 meters.
11.6 Laying Method of GRP Pipes
Pipes shall be laid in accordance with ASTM D 3839.
11.6.1 Control of Pipes before Laying
The pipes and the connecting pieces shall be examined before placing in the trench,
the inside and outside of them shall be cleaned; existence of any damage due to
transportation, loading and unloading shall be checked.
11.6.2 Lowering of Pipes into Trench
The vehicles and tools used for placing the pipes in the trenches shall allow uniform
lowering of the pipe, pipes shall not hit to the sides or edges of the trench during this
operation. During transportation of the pipes chain, steel ropes or similar materials that can
damage the pipe shall not be used. Carrying the pipes by passing a rope inside it shall not be
permissible.
64
11.6.3 Laying GRP Pipes
For the places of GRP sleeves used for connection of GRP pipes, head holes shall be
digged so that sleeves can lean through the pipe. The pipes to be connected shall be jointed
end to end at the same axis and lowered in the trench at this condition. Clips prepared for this
purpose shall be attached so that it will remain at the back of the sleeve for the pipes with
sleeves, and they shall be attached by considering the section of the pipe that will enter in the
sleeve for pipes without sleeves. The housing for the gasket at the inner surface of the sleeve,
shall be completely cleaned from dust and dirt. The gasket shall be correctly placed in its
housing by considering the direction of the gasket. After thoroughly cleaning the end of the
pipe to be connected, slippery paraffin or yellow soap shall be applied on the inner surface of
the sleeve and end of the pipe.
The tensioning apparatus used for connection of the pipes shall be attached to the clip
and shall be pushed through the sleeve of the pipe until it lean on the stopper at the middle
section of the pipe by the help of the tensioning. The connection place shall be supported with
filler material. The tensioning apparatus and the clips shall be removed sequentially, the
pipes, underside of the pipes and sides shall be supported with filler material. Pipe mounting
operation shall continue in this way. Angular deviation allowed according to the diameter at
the connection places of the joint sleeves are given in Table 9.
Table 9 - Angular deviation allowed in joint sleeves

Nominal pipe diameter(mm) Angular deviation(degree)
DN < 500 3.00
500 < DN < 900 2.00
900 < DN < 1800 1.00
DN > 1800 0.50
The maximum pressure deflection and long term deflection for laid and completely
covered pipe shall not exceed the values given in Table 10.
Table 10 – Allowable Vertical Deflection Values (In the degree of diameter percentage)
Ground class of the zone 1 2 3 4 5
Nominal diameter is 300 mm or more
Maximum Initial Deflection value 4.0 3.5 3.0 2.5 2.0
Long term deflection 6.0 6.0 6.0 6.0 6.0
The bottom of the pipes shall be adequately supported during laying and attention
shall be paid in order to prevent any open space between pipe and trench edges.
11.6.4 Rigid Connections and Fixing Blocks of GRP Pipes
Short GRP pipe 1 meter in length during passage to different natural grounds in GRP
pipeline.
Connections like bend, T, reduction, Y piece shall be supported with fixing blocks.
Short GRP pipe 1 meter in length at both sides of the fixing blocks. For pipes manufactured
by centrifugal casting method and in rigidness class equal to or more than 5000 N/m 2, there is
65
no need for using this short pipes 1 meter in length in these connections. Also for flanged
joints and similar rigid connections these short pipes 1 meter in length shall be used.
The fixing blocks shall completely cover the GRP pipe connecting pieces and
complete impede their movement.
11.6.5 Hydrostatic and Impermeability Tests of GRP Pipeline
Hydrostatic test shall be conducted regularly during mounting operations. The length
of the line mounted and to be tested shall not pass 1 km. Necessary controls shall be
performed before tests in order to check the correctness of the mounting of the section to be
tested. The important issues during this control shall be as follows:
Maximum deflection value related to the pipes shall not exceed the values given in the Table
10:
The connecting elements shall be checked again whether or not they are correctly
attached.
Pipeline, fixing blocks and other anchorages shall be correctly fixed in their places.
Flange screws shall be tightened to the specified torque value
Pipeline filling shall be completed. The connection places (sleeves) can be left as open
in pipes under 16 Atm nominal pressure. For pipes over 16 Atm nominal pressure, in order to
leave open the connection places (sleeves) on them, the line shall be fixed so that it cannot
move and the pressure value to be tested shall not be more than 24 Atm. In order to prevent
rotation and other movements of the sleeves they shall be covered.
Pumps and valves shall be anchored.
The power in the axial direction generated due to covering of the pipes at the test
points shall be supported and the loads in the axial direction on pipeline shall be prevented.
Water shall be fed to the system by opening the pipes. When pipeline is filling with
water, the air shall be discharged and fluctuations (variation) in the pressure shall be
prevented. The pressure in the pipe shall be slowly increased. An important amount of energy
is stocked under pressure; this power shall be kept in control. The manometer shall be placed
at the bottom part of the pipe so that it will indicate the highest pressure level in the pipe.
Attention shall be paid so that the maximum pressure values given in Table 11 shall not be
exceeded.
Table 11 - Maximum Field Test Pressure

Pressure Class Maximum Field Test
Pressure
6 Atm. 9 Atm.
10 Atm. 15 Atm.
16 Atm. 24 Atm.
25 Atm. 35 Atm.
32 Atm. 45 Atm.
If the required pressure can not be maintained at a constant value for a specific period,
the causes like temperature difference, expansion in the pipe and air pressed in the pipe shall
be checked (Glass reinforced plastic product pipe can expand under pressure. For this reason
the amount of water to be fed into the pipe shall not be more than expansion losses).
66
ASBESTOS CEMENT PIPE
1 GENERAL
These pipes are manufactured by wrapping a homogeneous paste consisting of cement

and 15% asbestos as thin layer by pressure. The asbestos cement pipes shall be in accordance
with TS 102, sleeves and special parts shall be in accordance with DIN 19802 – 19803 -
19804 – 19805 – 19806 – 19807, for issues not specified here they shall be compatible with
ISO, UNİ .B.S., S.A.BS. or an equivalent standard.
The Contractor shall give information about the specification of the material and
submit the specification to the Employer together with this information and after approval of
the Employer, the Contractor shall order for the material.
If the characteristics of the pipes supplied by the Contractor are not compatible with
the requirements of the Employer, the Employer shall prevent them from use and the loss due
to that reason shall be at the Contractor’s expense.
Asbestos wires are 15 micron in thickness. Asbestos wires act as fitting and the
thickness is calculated according to the required pressure. Asbestos cement mixture are
manufactured by pressing and wrapping on a steel cylinder as thick layers in 2-10 mm
thickness. The cylinder provides the inside diameter of the pipe and after waiting in water for
two weeks and drying, the ends of the pipes are corrected.
The asbestos cement pipes are more resistant to corrosion when compared with the
concrete, because asbestos and cement is a better and more homogeneous mixture than
concrete.
According to Sweden specification, the following conditions shall be met for asbestos
cement:
a. Water : pH > 6.5

T.S.D. > 3.5
Free aggressive CO2 < 35 mg/l .
b. Field : pH > 6
Sulphate (SO3) < 0.2%
Magnesia (MgO) < 2% .
Asbestos cement pipes are not effected from distributed current.
The pipe lengths are 4-5 meter, the diameters are 40-800,1000 mm. The valves are
metallic and generally they are connected to the pipes with metallic parts. The pipes cylinder
shaped Tee are manufactured from large diameters of fonts.
67
1.2 Characteristics and Manufacturing
The following tests shall be performed at the factories:
1 . Pressure,
2 . Crushing (Fracture by Peak Pressure),
3 . Bending,
4 . Impermeability.
1 . Pressure Test
Water is filled in water and the pressure is increases very slowly until pipe fractures. The
tension is calculated with the formula 1 = Pd/2e. In formula 1, P, inside diameter
d, wall thickness e shall be taken as kg/cm2, kg/cm2, cm, cm respectively.
2 . Fracture with Peak Pressure

The pipe 20 cm in length is carried throughout the pipe axis at the bottom and broken with
pressure from the top. Formula is  =3P(d+e)/e2L.
kg/cm2; P, load in kg; d inside diameter in cm; e wall thickness in cm and L pipe
length in cm. The pressure increase shall mot be more than 10 -20 kg/sn.
3 . Bending Test
The pipe up to 200 mm in diameter is carried till distance between supports is 2 m. Force
is applied in the middle of it. 3= 8PL/ . d+2e/(d+2e) 4-d4 kg/cm2. Here 3, P, D, L
length (opening), e shall be taken as kg/cm2, kg, cm, cm and cm respectively.
According to TS 102:
1 min. 200 kg/cm2 wet (pipe)

2
min. 225 kg/cm dry (pipe)
 min. 450 kg/cm
2
wet (pipe)
2
min. 500 kg/cm dry (pipe)
3 min. 250 kg/cm2 wet (pipe)
min. 275 kg/cm2 dry (pipe)
 VALUES ACCORDING TO VARIOUS NORMS

Norm : ISO BS AWWA DIN
Rago – 1960 486 - 1956 0 409 - 53 19800 - 1956
Explosion strength 200 kg 225 kg/cm2 225 kg/cm2 200 kg/cm2
2
due to internal /cm 3200 lb/sq.in. 3200 lb/sq. in. 2845 lb/sq. in.
hydraulic pressure 2845 lb/sq. in.
Crushing strength 450 kg 527 kg/cm2 527 kg/ 450 kg/cm2

2 2
due to external load /cm 7500lb/sq. in. cm 6400 lb/sq. in.
6400 lb/sq. in. 7500 lb/sq. in.
Bending strength 250 kg 280 kg/cm2 280 kg/ 250 kg/cm2

2 2
due to external load /cm 4000lb/sq. in. cm 3556 lb/sq. in.
3556 lb/sq. in. 4000 lb/sq. in.
 ISO : International norm, BS : British norm,

AWWA : American norm, DIN : German norm .
68
Water absorption shall not be more than 20%. The rings 2.5 cm in length are left in
15 – 18o of water for 18 hours and completely dried until there is not any water drop on it. It
o
is heated under 150o for 4 hours at and weighed. The ratio of weight difference to dry material
is water absorption amount.
Impermeability; for all pipes under 2 times of working pressure there shall be no
leakage, oozing and watering. It is applied for one connection per 200 pipes in the same test
and maximum deviation is introduced to the pipe in this test.
Since asbestos cement pipes are light weight, their transportation and placement is
easy. One master and one worker can lay 150-200 meter of pipe 500-600 mm in diameter and
500-600 meter of pipe 50-80 mm in diameter. The lightness provides economy for
transportation. Since they are too brittle they shall be carefully transported.
According to German norms the characteristics of asbestos cement pipe and collars are
as follows:
PIPE COLLAR
Inside Atm e d2 Weight Weight Length Outside Weight
diameter (mm) Outside (kg/m) with (mm) diameter (kg)
(mm) diameter collar (mm)
(mm) (kg/m)
50 12.5 9 68 4.1 4.4 120 109 1.2
65 12.5 9 83 5.4 5.9 120 124 1.8
80 10 9 98 6.3 6.9 120 143 2.2
12.5 10 100 6.7 7.3 120 147 2.4
100 6 9 118 7.5 8.1 120 143 2.4
10 10 120 8.7 9.3 120 147 2.4
12.5 13 126 10.7 11.3 120 179 2.5
125 6 10 115 10.6 11.3 120 194 3.3
10 12 149 12.8 13.7 120 202 3.7
12.5 14 153 14.3 15.4 120 210 4.4
150 2.5 10 170 12.3 13.2 120 219 3.4
6 11 172 13.0 14.0 120 223 3.8
10 14 178 17.8 19.0 120 235 4.7
12.5 17 184 20.8 22.0 120 247 5.0
200 2.5 11 222 17.5 18.5 140 275 4.8
6 13 226 22.0 23.1 140 283 5.5
10 18 236 28.5 29.8 140 303 6.5
12.5 22 244 35.5 37.1 140 319 7.9
250 2.5 12 274 23.5 25.1 140 331 7.9
6 15 280 30.0 31.7 140 343 8.7
10 19 288 37.5 39.5 140 359 10.0
12.5 25 300 49.0 51.1 140 383 10.7
300 2.5 14 328 32.5 34.5 170 390 10.2
6 17 334 39.5 42.1 170 403 12.8
10 23 346 54.0 57.1 170 427 15.6
12.5 30 360 69.0 72.3 170 455 16.7
350 2.5 15 380 40.0 42.5 170 445 12.3
6 19 388 51.0 54.2 170 461 15.8
10 27 404 78.0 76.8 170 493 19.0
12.5 35 420 94.0 99.1 170 525 25.5
400 2.5 18 436 55.0 58.3 170 507 16.5
6 21 442 65.0 68.8 170 519 18.9
10 30 460 92.0 96.4 170 555 21.9
12.5 40 480 120.0 126.4 170 595 31.9
69
Note : Weight tolerance : + 7%, Connections : Same with flat pipe connections.
The specific gravity is approximately 2000 kg/m3. The comparison by weight with
cast-iron pipe is as follows:
Diameter Cast-iron Pipe AC Pipe Weight(kg/m)

(mm) Weight(kg/m)
60 11.5 5.9
100 20.0 10.8
200 45.7 34.5
The mounting of the heads shall be in accordance with the recommendations of the
manufacturer. The gaskets used for heads shall be in accordance with the related international
standards acceptable to the Employer. Gibault and Reka Tayton are mostly used ones. Gibault
type is similar with the cast-iron pipes. For connections the flat pipes are pushed into the
collars by hand in case of small diameters, and by tensioning elements in case of large
diameters. In order to provide easiness, the pipe and the rubbers are lubricated with yellow
soap or glycerin. Before pushing the pipe into the sleeve, its end is marked 2.5 mm from the
sleeve and pushed until this mark or a ring is tightened at this distance. There shall be a
distance of 5-6 mm between both of the pipe ends. For the Reka type connection this
condition is met. The following deviations are permissible for the Reka type connection.
Diameter (mm) Diameter ( o )

50 – 100 6
125 – 175 5
200 – 300 4
350 – 400 3
The ends of cast-iron special parts to be used together with the asbestos cement pipe,
shall be processed to a shape and size suitable for mounting of sleeves (heads) related to the
pipe. With the approval and requirement of the Employer, normal cast-iron special parts with
abutment or brite special for cast-iron pipes shall be made use of by placing one end
appropriately to the joint sleeve and the other end to special transition parts with abutment or
brite.
The spurs and ends of the special part in contact with special part shall be in its set
square and lathed.
Fittings shall be the same with ones used for cast-iron and steel pipe plants.
Asbestos cement pipes can be cut by saw easily, drilled with gimlet, pass can be
opened, filed and rasped. The pipes can be cut at big diameters withy portable lathes and at
small diameters with taws.
The pipes are tried at the trenches with the half of the manufacturing pressure (factory
test pressure).
70
Branches can be made with asbestos pipes, but generally lead or copper pipes are
used.
In order to protect the pipe from shock effect, it shall be under a depth at least 1.2
meter for under roads and 0.8 meter for other places as the same with cast-iron pipes.
The issues taken into consideration for laying asbestos cement pipes are as the same
with that of cast-iron pipes.
The formulas and coefficients used for cross section calculations are as follows:
Formula : Coefficient :
Bazin  = 0.06
Kutter m = 0.12
Scimemi V = 64.28 d 0.28 I 0.56
Hazen Wilhams V = 1.318 CR 10.63 I 0.54, C = 140
Strikler V = 105 R 2/3 I ½
Colbrook K = 0.025 mm – 0.030 mm
Stucky V = 140 R 0.645 I 5/9
The roughness at the pipes is very small for the asbestos cement pipes. It is almost
considered as polished. This property does not change in time, in other words there is no
sedimentation by time.
2.1 Sampling, Pressure and Impermeability Test
Pipes ready for delivery shall be visually inspected in order to determine the
manufacturing faults. The faulty pipes shall not be accepted. Finally, sufficient number of
samples compatible with the standards shall be taken from each lot and they shall be subjected
to pressure and impermeability test after thickness control.
The pressure test shall be applied as 2 times of pressure class of the pipe at the factory
test.
2.2 Test Costs
The cost associated with the tests acceptable to international standards shall be at the
Contractor’s expense. The test and inspections shall be conducted at an official laboratory
determined by the Employer.
71
3 MARKING
Symbol of the part’s name (A, F, FR, K, etc.)
4 PACKAGING
without breaking.
5 CONTENT OF OFFER
the offer.
6.1 Acceptance
72
all the requirements at the end of the inspections and tests made on the test pieces that
represent the condition corresponding to the samples taken from the lot delivered, shall be
accepted.
6.3 Rejection
7 DELIVERY
marked.
them.
of 20%.
8 ORDER FORM

expense.
73
transportation.
Utmost care shall be taken during the transportation of the asbestos cement pipes, and
the pipes shall not be unloaded, loaded and stacked by throwing, rolling and dragging. The
transportation shall involve minimum loading/unloading operations. The pipes shall be always
lifted by hand and using rope, wooden beams, or lifting mechanisms or machines.
74
DUCTILE PIPES
1 SUBJECT AND SCOPE
This specifications describes the technical specifications, manufacturing and

manufacturing sufficiency, quality and quality control, sampling, as well as acceptance,
conditional acceptance and rejection criteria and delivery of fittings manufactured from
ductile cast-iron material. These fittings shall be used for drinking water system, water supply
pipeline and irrigation system by the General Directorate of State Hydraulic Affairs.
Ductile pipes are spheroid cast iron pipes manufactured by centrifugal casting method.
These pipes have high strength and flexible characteristics when compared with the usual cast
iron pipes. The pipes are coated with clay cement internally and bitumen over zinc externally.
1.1 Norms and Standards
The pipes and fittings manufactured from ductile cast iron shall be in accordance with
ISO 2531 Standard and shall be capable of passing from the tests defined in this
specifications. In addition to this, these pipes shall be in accordance with BS 4772 and DIN
EN 545.
1.2 Materials
The material used for manufacturing of fittings shall be spheroid nodular graphite
structure ductile cast-iron material.
When the material to be used in the manufacturing is compared with the cast-iron
material, the result shall be a material with higher tensile strength and less fragile (more
flexible) material.
The relation between the percentages in the iron, carbon and silicium alloy of the
material to be used in the manufacturing shall be as follows: % C + 1/3 % Si = 4.3
Nodular distribution between micro structure shall be at least 80 pieces/mm.
The Material hardness shall be maximum HB 250.
2 TECHNICAL CHARACTERISTICS
2.1 General
The manufacturing of the pipe pieces shall be completely in accordance with the
replaced ISO 2531-1979 (E), ISO 13 and ISO/R 79 standards. For issues not specified in these
75
standards, if the manufacturing principles of the manufacturer is compatible with the
internationally accepted standards, the Employer shall accept.
2.2 Molds
 The molds shall be made from sand or metal
 The attention shall be paid to the measurements (in mm) in the molds in order to
prevent any fault on the ductile cast-iron material due to the molds (holes, sand
deposits, cracks, splits, etc).
2.3 Working Pressure
The fittings shall be resistant to 16 bar of working pressure unless otherwise stated in
this project and specification.
2.4 Dimensions
The manufacturing dimensions of the fittings shall be in accordance with the table
values given in ISO 2531.
For dimensions not defined in the ISO Standard, manufacturer can recommend his
own standards. However, the manufacturer shall take the approval of the Employer before
production.
2.5 Thickness of Ductile Pipes and Fittings
Standard thickness of pipe and fittings is a function of nominal diameter and

calculated as follows:
e = K ( 0.5 + 0.001 ND )
Where:
e: standard wall thickness (mm)
ND: nominal diameter (mm)
K: the coefficient depending on the operational conditions of the pipe and fitting
In this specifications, pipe wall thicknesses shall be calculated by taking K=9.
The wall thickness of the fittings (except “T” parts) shall be calculated by taking
K=12. The wall thickness of the “T” parts shall be calculated by taking K=14.
76
2.6 Quality of Ductile Pipe, Fitting and Other Pipes
There shall be no defect that will prevent the use of pipes, fittings and other pipes. If
little defects are caused by the manufacturing method and do not impede the use, these
materials shall not be rejected. The Manufacturer can correct these little surface defect in a
suitable way provided that the responsibility shall be born by him.
2.7 Thickness and Mass Tolerances
Thickness and mass tolerances shall not exceed the values given in ISO 2531.
2.8 Maximum Working Pressure And Internal Pressure Test
The pipes shall be subjected to hydraulic pressure tests under minimum pressures
given in the table below for a duration of 300 seconds at the factory.
Nominal Diameter (ND) Test Pressure (bar)

80 – 300 50
350 – 600 40
700 – 1000 32
3 COATINGS
3.1 Internal Coatings
The coating surface shall be uniform and smooth, on the coated surface there shall be
no cracks or blisters on the mortar, and the surface shall be smooth and regular.
It shall stick on the inner surface of the pipe without any spaces, before coating
application, the surfaces to be coated with cement shall be cleaned from cast sand and cast
spallings and all other foreign substances in order to provide complete contact with the
coating mortar.
In case of cement mortar, the manufacturing and quality of the cement material shall
be in accordance with the last amendment of the ISO 4179 standard.
In case epoxy is used for internal coating, the company can make isolation with epoxy
instead of cement. The related DIN 30677 standard shall apply for epoxy.
In case of polyurethane, the inner and external coating of cast-iron ductile pipes
manufactured in accordance with ISO 2531, can be proposed with suitable polyurethane
compatible with the international standards in addition to its norms.
77
In case of proposals for polyurethane coating, the conformity of the technical
characteristics of ISO 2531 related to the all technical characteristics determined in this
specifications with the internationally accepted standards related to the polyurethane coating
shall be provided.
In case the internal coatings are proposed as cement mortar, epoxy or polyurethane,
the proposal shall include a certificate taken from an independent international health
organization in order to certify that the internal coatings are not harmful to health.
3.2 External Coatings
Ductile cast-iron pipe and pieces shall be coated with zinc in order to control the
corrosion. The zinc shall be 99.9% pure and the application shall be with spraying method.
The distribution shall be 130 gr/m².
The zinc coating shall be covered by black bitumen 70 micron in thickness. The
bitumen to be coated shall be resistant to all types of climatic conditions, the chemical
composition and application method shall be provided in the proposal.
The external coating shall continue up to the internal section of the pipe connecting
element with ambuatman.
The inner surface of the shell section (not in contact with water) of connection piece
with sockets shall be coated with bitumen and isolated.
Drinking Water Pipes
The inside of the drinking water pipes shall be coated by rotary cement mortar. The
mortar shall not contain toxic or materials soluble in water and elements give odor to the
water. The characteristics, placement and control of the mortar shall be in accordance with
ISO 4179.
The mortar shall be prepared by mixing one part of cement and 3.5 part of sand, in
other wards sand/cement ratio shall be equal to or less than 3.5. The quality control shall be
performed in accordance with ISO 6600. For pipes with nominal diameter less than or equal
to 250 mm, the outer surface shall be applied with electrolyte zinc protection. In addition to
this, a black paint shall be applied on the outer surface of all the pipes at the factory. Before
laying the pipes, a bitumen based special hot coating in accordance with BS 4147 standard
shall be applied on the outer surface for a minimum 0.3 mm thickness in order to provide
protection for corrosion.
Pressurized Sewer Pipeline
The inner surface of the pipes to be used for pressurized sewer lines shall be coated
with polyethylene in accordance with DIN 30674. For pipes with nominal diameter less than
or equal to 250 mm, the outer surface shall be applied with electrolyte zinc protection. In
addition to this, a black paint shall be applied on the outer surface of all the pipes at the
factory. Before laying the pipes, a bitumen based special hot coating in accordance with BS
78
4147 standard shall be applied on the outer surface for a minimum 0.3 mm thickness in order
to provide protection for corrosion.
4 HEAD CONNECTIONS
4.1 Pipes with Socket and Spigot
Unless otherwise specified, the pipes with socket and spigot shall be used throughout
the under ground pipeline as specified above. All connections shall be standard and in a type
shall be easily seated in their places. The spigot and sockets shall act as connecting elements
at the pipes. The joints shall be sealed with gaskets.
Inside the socket:
For gasket, there shall be a deep recess with seating places in the ring form and a long
space allowing angular and longitudinal movement of pipes connected to each other. The
gaskets shall have a strong body and two thick cheeks extending through the bottom of the
socket. There shall be a projection in the ring form suitable to the recess of the socket on the
outer surface of the gasket body, for the side of the projection facing the entrance of the
socket there shall be a chamfer for providing complete seating at the socket recess.
In order to provide complete impermeability and sufficient degree of flexibility,

standard gaskets shall be molded to have a wide cross section covering the wide seating
surfaces. Water tight gaskets shall be used for drinking water or sewer pipes.
The maximum continuous operational temperature of the gaskets shall be 70o C. The
gaskets to be used for pipes between 60 mm and 1000 mm in nominal diameter, shall be
manufactured in homogeneous form from natural rubber or equivalent elastomer based
materials.
The gaskets shall be stored under the following conditions:
The storage temperature shall be between +5o C and +20o C. If these gaskets are stored
at lower temperatures, necessary attention shall be paid during transportation and usage in
order to prevent deformation and shall be kept at approximately 30o C temperature for a
sufficiently log time so that it can gain its original elasticity before being used.
The factors that shall be avoided for elastomer based vulcanized products:
They shall not be stored under very dry or very humid conditions, they shall not be
exposed to direct sun light or infrared rays, shall be protected from atmospheric conditions
and particularly effects of ozone.
4.2 Flanged Pipes
All the pipes that are not buried (such as the pipes at the pumping stations) shall be
flanged and the internal coating shall be as specified above.
79
The external coatings shall be as specified above except from the bitumen at the
factory and after application of coating, several layers of paint shall be applied, and the color
of the finishing paint shall be determined by the Employer.
Flanged Water Pipes
The flanges of the flanged water pipes shall be bored according to NG16.
The Flanged Pipes Used for Pressurized Sewer Lines
The flanges of the flanged pipes to be used for pressurized sewer lines shall be bored
according to NG16.
The mounting of the flanged joints shall be as follows:
The parts to be connected are aligned. The places are adjusted so that the bolt holes
stay face to face. A space is left between the flanges for gasket. The bolts are mounted by
placing gaskets between the flanges.
The gasket is seated between the projections on two flanges.
The nuts are mounted and the operation is completed by tightening the two nuts at the
two corresponding sides of the pipe diameter.
The gaskets used in the flanged joints shall be prepared by cutting elastomeric layers
one side textile coated and uncoated. For the water and waste water pipes natural rubber
gaskets shall not be used. Textile coated gaskets shall not be used for NP 10 and NP 16
flanges.
The storing conditions of the gaskets are the same with the conditions given for rubber
gaskets specified in “Pipes with sockets and without socket” title.
4.3 Fittings and Connecting elements
The fittings shall be in accordance with ISO 2531, wall thicknesses shall be designed
according to K=14 at T pieces and K=12 for all the fittings. The flanged fittings shall be
drilled at NG 10 or NG 16 size as required for the pipes. The fittings shall be subjected to
impermeability test under the pressure applied on the pipes as project requirement at the
working place.
During laying of the pipes on the water supply pipeline and water system, they are the
pieces used for providing new branches when changing the direction of the pipelines,
terminating the ends of pipelines when changing diameter and connecting the pieces under
certain circumstances (They shall be referred as “Connecting elements” or “Fittings”).
80
5 GASKETS
Gaskets shall be as specified in ISO 2531, catalogue and the drawings shall be
supplied in the proposal. The quality of the rubber gaskets and technical specifications to be
used at connecting elements shall be in accordance with the last amendment of BRITISH
STANDARD 2494.
The gaskets to be used for connections with abutment shall be from natural rubber or
equivalent material.
The gaskets to be used for flanged joints shall be 3 mm in thickness and fiber
reinforced. They shall be fiber cotton type.
The gaskets shall not be delivered separately but they shall be delivered as mounted in
the connecting elements.
“GASKETS” shall provide clamping of Ductile Cast-iron pipes and their “connecting
elements” in order to provide impermeability, they shall be produced from rubber or
equivalent material.
6 BOLTS AND NUTS
Bolts and nuts are mechanical elements coated with zinc that are used for connection
pipe pieces from the holes drilled on the flanged joints.
The bolts and nuts to be used for flanged joints shall be calculated according to flanges
prepared in accordance with ISO 2531 PN 16 and their quantities shall be specified in the
proposal.
7 TOLERANCES
7.1 Thickness Tolerances
The wall thickness of the pipe shall be as follows:

The standard thickness is expressed in b/mm. "DN" is the nominal diameter.
Dimension Tolerance
--------- ------------
Fitting wall thickness -(2.3. + 0,001DN)
Flange thickness ± (3 + 0,05 b)
7.2 Manufacturing Lengths and Length Tolerances
The length tolerances of pipe connections shall be in accordance with ISO 2531-1979
(E) section 4, depending on the composition of casting for shrinkage and expansion and
thermal application and shape of the piece.
81
7.3 Mass Tolerances
The mass tolerances of each type of connecting element shall be in accordance with the
international standards. The manufacturer shall show each of them per part in his catalogue.
a) Approximately 0,1 kg for masses 20 kg or less.

b) Approximately 0,5 kg for 20 kg- 100 kg
c) The tolerance in normal mass shall be % ± 12 for masses higher than 100 kg
7.4 Coating Tolerances
If the cement mortar is internal coating shall be in the sizes specified in ISO 4179 -
1985 (E), the cement, sand, organic substances in the cement mortar, water ratio shall be
clearly stated.
In case the internal coating is applied with epoxy, it shall remain within the tolerance
limits specified in DIN 30677.
For gaskets: it shall be stated that there is no cracks during ozone tests and hardness
change at low temperatures, swelling, water absorption, pressure reducing, compaction,
hardness (micro test), extension during fracture, tensile strength.
For that reason a comparison table covering the characteristics given above shall be
included in the proposal. In this table the acceptable tolerances are provided by comparing the
proposed gasket type and the gasket type specified in BS 2494 (1986).
8 SAMPLING AND TESTS
8.1 Sampling
Sufficient number of samples shall be taken from each lot ready for delivery in
accordance with the standards and the samples shall be subjected to mechanical,
metallographic and chemical tests.
8.2 Manufacturing Tests
a) Chemical tests (measurement of element and determination of nodular structure)

b) Hydrostatic test (under 25 atm pressure for 15 seconds) shall be applied for 100% of the
parts.
c) Tensile tests
d) Brinnel Hardness test
e) Inner and external coating tests:
82
The products shall be subjected all the tests mentioned above before being delivered to
the Employer and the Contractor shall submit a certificate taken from an international audit
company in order to certify the performance of the tests for each lot being delivered.
8.3 Tests and Inspections at the Time of Entrance into the Employer’s Warehouse
8.3.1 Physical Inspection
The parts whose coating is spilling, cracked, crushed or having another observable
defect shall be refused.
Sufficient number of samples which are in accordance with the standards shall be
taken from each lot of product, and the samples taken shall be subjected to metallographic,
chemical or physical inspections.
For sampling, the Contractor shall prepare and send sufficient number of test bars
related to the lot together with each lot to the Employer.
8.3.2 Chemical Inspections
The analytic structure of the metal shall be controlled.
8.3.3 Metallographic Inspections
The structure and numbers of the nodules in micro structure shall be inspected and
investigated, the nodular structure and number of nodules of the surfaces branded with dicral.
The parts shall have full spheroid graphite structure and shall have at least 80 nodules/mm3.
8.3.4 Mechanical Inspections
1. Pressure and Impermeability Tests
Samples shall be subjected to pressure and impermeability tests at least for 15 seconds
in hydraulic circuits prepared earlier. The pressure applied for this test shall be 1.5 times of
the working pressure (approximately 25 bars). Under 25 bar pressure there shall be no leakage
and oozing on the piece.
2. Tensile Test
Test bars prepared and cast suitable to its method from cast charge of connecting
pieces shall be subjected to tensile test. The tensile strength values shall be at least 40-42
DAN/mm.
83
3. Hardness Test
The samples shall be subjected to hardness test. The products up to 250 HB of

hardness degree shall be accepted.
4. Cross section inspection
The samples shall be cut at suitable workbenches. Part wall thicknesses shall be in
accordance with the standard and homogeneous at each point.
8.4 Coating Tests
In case cement mortar is applied for internal coating, the cracks on the coating shall
not exceed 0.8 mm. The coating thickness and characteristics mentioned in Clause 7.4 shall be
investigated in the tests.
In case epoxy is applied for internal coating, tests specified in DIN 30677shall be
performed.
The external coating and zinc inspection shall be subjected to test with methods
specified in international standards.
8.5 Test Costs
The cost associated with the tests acceptable to international standards shall be at the
Contractor’s expense. The test and inspections shall be conducted at an official laboratory
determined by the Employer.
9 MARKING
Symbol of the part’s name (MMA, FFR, MK, etc.)
Special marks for each casting charge
84
10 PACKAGING

Packing crates shall be strong enough to enable the transportation of the materials
without breaking.
11 CONTENT OF OFFER
The Contractor shall state in its offer the quantities, unit prices, and FOB-C+F-CIF
total prices of the parts, both individually and in total, together with the symbols shown in the
list attached hereto.
The Contractor shall clearly explain in the quoted price whether or not the internal and
external coating is included in it (preferably, these should be included).
The necessary gaskets shall separately be stated, clearly indicating their unit and total
prices.
The quantities of bolts and nuts for flanged parts shall be calculated, including in the
offer the unit and total prices.
the offer.
These are:
a) The chemical test results of ductile cast-iron pipe piece

b) Nodular distribution
c) Hardness
d) Wall thickness
e) Weight
f) All physical and chemical characteristics of internal or external coating
g) The characteristics of the gaskets in Clause 7.4.3
h) Tensile tests
i) The results under hydrostatic tests shall be considered and clearly specified for each
part if necessary
85
12 ACCEPTANCE- CONDITIONAL ACCEPTANCE - REJECTON
12.1 Acceptance
all the requirements of Article 3, at the end of the inspections and tests made as per Article 8
on the test pieces that represent the condition corresponding to the samples taken from the lot
delivered, shall be accepted.
12.3 Rejection
13 DELIVERY
marked.
them.
of 20%.
14 ORDER FORM
86

expense.
transportation.
In the construction site, the pipes shall be stored on an elevated ground so that the
spigot ends do not contact with the soil, and supported by the frameworks.
Pipes can be stored in such manner that both ends be placed either face to face or at
the same direction.
87
CONCRETE AND REINFORCED CONCRETE PIPES
1 GENERAL
Concrete pipes shall be used for sewerage, storm water, wastewater, and similar
purposes.
Concrete pipes, fittings, and gaskets shall generally conform to the provisions of DIN
4032, 4033, 4034, and 4035. Type of concrete used for manufacturing the pipes shall conform
to "DSİ Concrete Works Special Technical Specifications". Concrete additives shall be
subject to the Employer's approval and may only be used after obtaining necessary consents.
Steel fittings for concrete pipes shall be manufactured in accordance with the applicable steel
works standards and specifications.
2 MANUFACTURING OF CONCRETE AND REINFORCED CONCRETE PIPES
Concrete and reinforced concrete pipes shall be manufactured by using two methods:
a ) Vertical casting and vibration method,

b ) Spinning method.
2.1 Vertical Casting and Vibration Method
Mortar is placed in a vertical formwork to obtain a height of 8 to 10 cm and then

compacted with a rod-shaped mallet. But, a uniform compaction cannot be achieved by using
this method. Sections compacted excessively or loosely are observed at every 6 to 8 cm in a
pipe so cast (because the thickness of mortar is reduced from 8 to 10 cm to 6 to 8 cm). Placing
mortar in a formwork and compacting it by vibration is more successful because satisfactory
pipes cannot be manufactured by using this method. This second method also increases the
rate of production and external and internal formwork give required integration. Dry mortar is
used and water/cement ratio is 0.4. 50 to 60 pipes can be cast daily. Proportion is usually 300
to 350 kg. Granulometry is usually 0-2, 2-20, and 20-30 mm.
2.2 Spinning Method
A metal formwork is placed on platforms and the formwork turns rapidly when the
platforms are rotated. When mortar starts pouring inside the formwork, the funnel is retracted
so that mortar spreads to all parts.
A satisfactory result can be achieved only if this method is used by experienced and
qualified workmen. The formwork is rotated slowly initially (in order to spread mortar) and
then rapidly in order to compact it. The whole process is completed in three to 20 minutes.
More time is needed for a larger mass of concrete. Cement forms a rich glossy layer inside of
the formwork. Concrete is rotated 8 to 15 meters per second.
88
Compact and impermeable pipes of high quality are manufactured by using the
spinning method.
Steel rods used in reinforced concrete pipes have various diameters, including 6, 8, 10
and 12 mm. Transverse steel rods are manufactured in helical form. Longitudinal steel rods
are connected to transverse steel rods by welding or wire. Steel mat may also be used
according to newly developed Technologies. Steel rods are recommended to be placed only in
the middle section in pipes with a small diameter and in the internal and external pipes in case
of pipes with a larger diameter. Pipes shall be so designed to withstand internal and external
pressure.
3 CLASSIFICATION
Concrete pipes to be used shall be classified into following categories:
a) Concrete pipes without reinforcement (inside diameter 600 mm or less)

b) Reinforced pipes (reinforced with steel rod or steel mat but not pre-stressed)
c) Pre-stressed reinforced concrete pipes with a diameter larger than 600 millimeters.
Reinforced concrete pipes shall have the following characteristics:
 A reinforcement cage (or cages) consisting of steel rods, steel mat or welded mat,
 A layer of dense concrete covering the reinforcement cage or cages,
 A preformed sealing in order to provide a spigot joint or a socket connection
automatically inserted with a rubber ring,
 PVC coating material cast together with the pipe for diameters equal to or higher
than 500 cm if required by the Employer.
Reinforced concrete pipes shall basically have the following characteristics:
There shall be PVC coating material capable of being cast together with the pipe
where applicable, a preformed sealing in order to provide a spigot joint or a socket connection
automatically inserted with a rubber ring.
4 QUALITY AND TESTING OF MATERIALS
The quality of reinforcement for concrete pipes shall conform to DIN 488 TI
requirements and B St 22/34 quality.
Quality of concrete for pipes shall conform to DIN 4032, DIN 4035, DIN 1045 or
"DSİ Concrete Works Special Technical Specifications" where applicable. No
reinforcement shall be used for the manufacturing of pipes unless materials are tested
generally in accordance with the Technical Specifications. Certified copies of the test
certificates shall be submitted to the Employer.
89
5 TYPES OF FITTINGS
Except as otherwise specifically provided herein, fittings for concrete pipes shall be of
spigot and socket types. The fittings shall be manufactured in accordance with the requirements
set forth in the applicable standards (DIN 4032 and DIN 4035) and manufacturer's
recommendations in case of pipes manufactured in factories.
6 SEALING OF FITTINGS
Fittings between pipes shall be sealed by sealing rings made of styrene-butadiene

rubber where required. Sealing rings shall be stored in well protected covered areas and rings
of different types and/or sizes shall be stacked separately. Delivery lists shall be drawn up and
submitted to the Employer.
Materials shall be applied in accordance with the manufacturer's recommendation and

pipe fittings shall be of quality guaranteeing sealed connections.
Lubriating materials for sliding fittings shall be of a type not causing an abrasion
effect on rubber rings and pipes and they shall not be affected by liquids flowing through
pipes.
7 APPLICATION DRAWINGS AND CALCULATIONS
The contractor shall provide construction drawings and calculations covering ancillary
components of concrete pipes depending on various bedding types in accordance with the
applicable specifications. Calculations shall be based on geotechnical data obtained by the
Contractor as a result of his own examinations at pipe depths shown in drawings in
accordance with DIN 4032, DIN 4035 and DIN 1045 depending on maximum traffic load
classification (SLW 60) as defined in DIN 1072.
The static calculations of pipes shall be done by using the detailed calculation method
outlined in the publication entitled "Arbeitsblatt A 127 “Richtlilie für die statische
Berechnung von Entvasserrungskanalen und – leitungen-.Ein Regelwerk der
Abwassertechnischen Verein igung e. v. (ATV). December 1984”. The calculation method
and procedures are as follows:
1 ) They will cover the creation of pipe data (pipe sizes, pipe test load, the flexibility
coefficient of pipe materials). They shall conform to safety class A127.
2 ) Determination of soil conditions and geotechnical parameters.
The existing soil shall be classified in accordance with DIN 18196 and A 127.
In situ density shall be determined as the percentage of maximum dry density.
Separate soil surveys shall be conducted in the pipe gaskets in order to monitor the
level of underground water. The Contractor shall create the geotechnical parameter
estimations of the existing soil needed for its own calculations. Unless otherwise agreed with
the Engineer, pipe calculations shall be based on the assumptions given hereinafter. Pipe
bedding types shall be derived from the drawings.
90
Material surrounding pipes above the bedding shall be screened soil such as group G1
or G2 in A 127.
Backfilling shall be excavated material suitable for required compaction.
Material surrounding pipe and backfilling shall be compacted to the same density as
the surrounding soil, which has not been excavated or at 100% of maximum dry Proktor
density as defined in A 127.
3 ) Creation of pipe trench data: soil cover, the width of the trench at the upper pipe level,
excavation profile, solder pile and working method shall comply with the specifications.
4 ) Calculation of load on pipe: Load on pipe shall be calculated depending on soil, traffic,
underground water, pipe fixed load and water filled in the pipe.
5 ) Calculation of stress: Vertical forces, torsion moment and stress above, below and within
the pipe shall be calculated.
6 ) Safety Check: Safety factors shall be applied in accordance with safety class A 127 in
order to determine whether stress is above the permitted level.
The Contractor shall make calculations for pipes with different diameters depending
on all differences observed in pipe depths (intervals of differences shall not be above 0.5
meter) and different soil conditions, working methods, etc.
Calculations shall be made systematically by using a computer program and submitted

in a form acceptable to the Employer. Such programs shall also be furnished to the Employer.
The following details shall be specified on the pipes to be supplied:
Spigot and socket,

Circumference of the sealing ring in loose position
The thickness and shape of the sealing ring
Permitted angular deviation
Form of bedding required depending on different load and soil conditions.
Calculations shall be approved by the Employer before the pipes are manufactured or
an order is placed. The Contractor shall be fully responsible even if the calculations have been
approved by the Employer.
8 SUPPLY OF CONCRETE PIPES
8.1 Concrete Pipes without Steel
Concrete pipes (with a diameter equal to or less than 600 mm) to be provided and laid
by the Contractor shall be as shown on the drawings or defined in the measurements.
Concrete pipes without steel shall be manufactured by using type V sulfate resistant concrete
with minimum characteristic resistance of 45 N/mm2 in accordance with DIN 4032 and DIN
1045 and conform to provisions of the Technical Specifications.
91
The plane of pipe ends shall be vertical to the longitudinal axis of the pipe except for
special shapes.
Its internal surface shall be smooth and surfaced.
There shall be no crevice, crack, or scaling on the finished pipe and it shall have a
smooth surface.
8.2 Reinforced Concrete Pipes
Reinforced concrete pipes (with an inside diameter over 600 mm) shall be
manufactured of concrete prepared by using Type V sulfate resistant cement. Minimum
characteristic resistance shall comply with 45 N/mm2 in accordance with DIN 4032 and DIN
1045.
Surrounding steel reinforcements shall be made of continuous or welded steel rods or

coils manufactured by welding in helical shape on condition that sectional area is minimum
1% of the concrete sectional area for each meter of the pipe on welded mats shall be
connected end to end or there shall be corbels. Surrounding rods or wires in the cage(s) shall
be adjusted and affixed so that they will have precise intervals by means of longitudinal rods
or wires affixed to them (by using an approved method). Distance between the two coils of
the spiral reinforcement shall be less than 150 mm. Layer to cover the fittings shall be 25 mm
thick unless the Employer requires otherwise.
Concrete pipes shall be manufactured either by using the centrifuge method or by

casting vertically in a steel formwork and subjected to mechanical vibration during
manufacturing.
8.3 Coated Concrete and Reinforced Concrete Pipes
Pipes with an inside diameter equal to or above 500 mm used for carrying waste water
by gravity shall be coated with PVC plastic coating materials.
Pipes shall conform to the requirements related to concrete and reinforced concrete
pipes set forth above. Bearing or corrosion clearance parts between reinforcing bars and
formwork or bottom chord shall be stainless steel or a non-metal materials approved by the
Employer and the bearing or corrosion tolerance part shall not come into contact with the
coating layer.
8.3.1 Concrete and Reinforced Concrete Pipes
Pipes containing any of the following defects shall be rejected:
1. If any part of a pipe has been broken irrespective of the size of the broken part;
2. Defects indicating inappropriate concrete mixture or coating;
3. Any crack the longitudinal or transverse length of which is wider than the wall
thickness of the pipe;
4. If the concrete around the crack has become crumbled or stratified;
92
5. If the deviation from the specified wall thickness is above 6.5 mm in case of pipes
with a maximum diameter of 750 mm or 6% in case of pipes with an inside diameter above
750 mm. Deviation may be connected to the longitudinal fitting on condition that it is not
close more than 20% of the inside diameter in the vertical axis of the pipe along the axis and
the fitting section of the pipe and does not extend more than 20% of the inside diameter
around the circumference of the pipe.
Permitted deviations from wall thicknesses shall not be applied to surfaces coming
into contact with gaskets in case of pipes with gaskets. The sizes and tolerances of such
contact surfaces shall be submitted for approval.
6. A deviation above 1% of the real circle of the specified inside diameter of the pipe;
7. Stone or water cavities in any pipe;
8. The exposure of any reinforcement or insufficient thickness of corrosion tolerance;
9. Presence of honey-combed or open texture surface defects;
10. Separation or swelling;
11. Any visible crack with a minimum continuous length of 0.50 mm or any crack inside or
outside with a minimum interruption of 1.00 mm in case of a sewerage pipe (except for cracks
caused during an external loading test specified in these Technical Specifications).
12. Any continuous crack with a minimum surface width of 0.25 mm and a minimum length
of 300 mm irrespective of the depth or place on the pipe wall.
13. If the pipe fails in the resistance test.
8.3.2 Coated Concrete and Reinforced Concrete Pipes
A pipe coated with plastic coating material may be rejected due to any of the
following reasons:
1. If the cover or bearing used for securing reinforcement structure at its place other than
the rings used for carrying or the reinforcing steel on the surface of the pipe is exposed.
2. The transversal reinforcing steel has shifted more then 6.5 mm from its specified place
after the pipe has been placed in formwork.
3. If the concrete around the crack has become crumbled or stratified;
4. If air bubble cavities with a depth exceeding 6.5 mm on the internal or external surface
of the pipe have not been filled with mortar or other approved materials.
5. If the pipe has been coated by cement or slurry without authorization.
6. If the wall thickness of a pipe with a maximum inside diameter of 750 mm is more than
7.5 mm thinner than the specified thickness.
7. If the deviation from the specified wall thickness is above in case of pipes with an inside
diameter above 750 mm. Deviation may be connected to the longitudinal fitting by 8%
on condition that it is not close more than 20% of the inside diameter in the vertical axis
of the pipe along the axis and the fitting section of the pipe and does not extend more
than 20% of the inside diameter around the circumference of the pipe.
Permitted deviations from wall thicknesses shall not be applied to surfaces coming
into contact with gaskets in case of pipes with gaskets. The sizes and tolerances of such
contact surfaces shall be submitted for approval.
8. If there is a deviation from the specified inside diameter and there is retreated internal
surfaces after the concrete has been poured. The permitted deviation from inside
diameter shall not be applicable to the joint contact surface of an attached pipe with a
joint.
93
9. A water cavity longer than 750 mm or three times wider than the specified wall
thickness (it shall be determined by hitting the internal surface of the pipe gently. Such
defective areas not exceeding those limits shall be repaired as specified in the
Technical Specifications.).
10. If one or more part at the end of the pipe has been broken and it is longer than 60 o of
the circumferential length of the circle or extends to the body of the pipe or has a
circumferential length exceeding 150 mm in an attached pipe with a joint (which
intersects the central point of the joint contact surface at the end of the pipe bell, then
the total length of all those broken parts at any end shall not exceed a length equal to
9o section of the circle and there shall be solid concrete with a minimum width of 230
mm between the broken sections. The total length of the broken sections of an
attached pipe with a joint extending to the joint contact surfaces shall not exceed a
circumferential length of 150 mm. Unsound sections at the end of the pipe shall be
removed and if the removed parts do not exceed the limits specified above, the pipe
shall be repaired in a similar manner.
11. Defects showing that the concrete has not been formed properly or a faulty area
exposing surface defects with a hole or open texture (air cavities) larger than a square
one side of which is 2.5 times the wall thickness or defects deeper than the size of
screened maximum aggregate or local concrete defects exceeding the limit specified in
(9) and (10) above when the defective concrete is removed. Defects not exceeding
those limits shall be repaired as specified in (9) and (10) above. Sand images
appearing at the end of the pipe may be repaired for the whole circumference.
12. Any of the following cracks :
(a) a crack which has a minimum width of 0.25 mm along a continuous line which is
minimum 0.30 mm long;
(b) any crack, which is longer than the pipe's wall thickness and extends along the wall of
the pipe;
(c) any crack which is minimum 0.60 m long and shows two separation lines or with a
minimum interruption of 0.90 meters on any internal or external section.
Any crack which is 0.25 mm wide and does not constitute a reason for rejection shall
be filled with pure cement slurry consisting of mixed cement and water in fluid consistency.
8.4 Repair of Defects
8.4.1 Method I Manual Repair with Mortar
8.4.1 .1 Preparation of Surfaces to be Repaired
Concrete, which is not strong or smooth, shall be removed by scraping. Sides where
the concrete has been scraped shall be sharp and consistent with the surface and no sides with
pointed edges shall be left.
94
Surfaces within the prepared areas shall be kept wet for several hours and preferably
overnight before the repair. All surfaces on the areas to be repaired shall be humid but not wet
when the material is applied.
8.4.1.2 Placement of Mortar
Mortar to be used for repairs shall have the same mixture of sand and cement as the
mixture used for manufacturing the pipe. In addition there shall be an admixture for
expansion.
The mortar shall be mixed until it absorbs water and acquires plastic consistency as
much earlier as possible before it is used. Trial mixtures shall be prepared and kept for a
certain period in order to determine the longest delay period during which mortar will have
sufficient plasticity permitting good workmanship.
Wetted surface of the area to be repaired shall be rubbed thoroughly with a little
amount of dense cement slurry by using a wire brush immediately before the application of
mortar. Loose sand grains remaining on the surface shall be swept away immediately before
applying mortar.
Care shall be taken to prevent air bubbles that can remain in the cavity to be filled by
mortar and to ensure that the sides are bonded together.
Surfaces shall be formed and completed so that they are at the same level as the
surface of the adjacent pipe.
Any hole or small defective areas on the surface shall be repaired by using "ready-
mixed mortar" with required characteristics.
Curing
Newly repaired surfaces shall be kept humid for 24 hours after the completion of the
repair. They shall later be covered by a membrane made of an approved white painting
substance.
8.4.1.3 Method II Repair by Using Mortar Applied by Pressure (MABP)
MABP shall not be used if the repair extends to the area below the section where the
reinforcement bar is exposed. Such repairs shall be carried out by using mortar, which has
hardening consistency.
8.4.1.3.1 Preparation of the Surface to be Repaired
Surfaces where MABP is to be used shall be prepared as defined in the Technical

Specifications. As an exception, the sides of the areas where the concrete has been removed
shall be cut if they are not sound or smooth so that reinforcement bar is not covered.
95
8.4.1.3.2 Placement of Mortar
Mortar shall be prevented from spreading or spilling. Pipe shall be rotated so that the
repaired area is placed vertically on one side and spillage is prevented.
Mortar to be used for repair shall contain the same ratio of cement and sand as the
mixture used for manufacturing the pipe.
A form ring shall be placed before repairing spigot ends of grooved concrete and the
form ring shall remain in the same place until the joint groove has sufficient resistance so that
no damage occurs.
The areas where MABP is used shall be cured as defined in the Technical
Specifications.
Curing
The areas where MABP is used shall be cured as defined in the Technical
Specifications.
8.4.1.4 Method III Repairs by Using Bonding Mortar with Epoxy Resin
Concrete sections, which are not sound or smooth, shall be removed by using a
concrete chisel. If mortar placed manually is used, the sides shall have a sharp and cornered
edge. If MABP is used, the sides shall be incluned. The area to be repaired shall be kept dry.
Loose material or concrete dust remaining after cutting shall be removed by compressed air.
Epoxy resins, which have been approved by the Engineer for such uses in advance,
shall be used as bonding material as specified by the Engineer. A first coat consisting of an
epoxy resin compound and care shall be taken to ensure that there is full contact. Mortar shall
be applied before the epoxy resin compound hardens. Mortar shall be applied by using
Method I or Method II as specified in the Technical Specifications.
The following tests shall be conducted on the pipes at the place of production.
Pipes ready for delivery shall be inspected visually in order to find out whether or not
there is any manufacturing defect and defective pipes shall not be accepted. An adequate
number of samples shall be taken from each lot in accordance with the applicable standards.
The samples shall be subjected to pressure and waterproofing tests after checking their
thickness.
96
9.1 Waterproofing
Concrete pipes and their fittings shall be subjected to testing against cracks as defined
in DIN 4032. In addition, pre-stressed concrete pipes shall also be subjected to concrete
density (water penetration) tests in accordance with the requirements set forth in DIN 1048
TI.
9.2 Resistance of Pipes
Concrete pipes and reinforced concrete pipes shall be subjected to resistance tests in
accordance with DIN 4032 and DIN 4035, respectively.
9.3 Cost of Tests
The costs of tests acceptable in accordance with international standards shall be paid
by the Contractor at its own expense. Inspections and tests shall be conducted at the factory or
a laboratory of a public agency to be designated by the Employer.
10 MARKING
The name of the Employer
Manufacturer's emblem or descriptive mark
Symbol of the part’s name
11 CONTENT OF OFFER
If gaskets are to be offered free of charge, this should be indicated in the offer.
and its parts shall be indicated separately and their detailed technical values shall be provided
in tables.
97
12.1 Acceptance
The result of tests conducted by using samples taken from a lot delivered shall be
deemed to represent the outcome of the test fort he whole lot.
If 2% of the samples taken for the inspections referred to above are found to be
defective and the Contractor is able to remedy such defects, then the lot in question shall be
accepted conditionally.
12.3 Rejection
Any lot, which is found not to be compliant with the required specifications and
tolerances as a result of the tests conducted by using samples, shall be rejected.
13 DELIVERY
As described above, the pipes shall be delivered to such place or pipe storage as will
be designated by the Employer.
of 20%.
14 ORDER FORM

expense.
98
Concrete pipes shall be transported and stored in accordance with the applicable
Technical Specifications and the directives set forth in DIN 19695.
Pipes shall be supported by wooden planks or laths not only at the bottom row and
between rows but also from their sides, ends and top in order to prevent any accidental
damage during transportation.
Utmost care shall be taken during the transportation of the pipes, and the pipes shall
not be unloaded, loaded and stacked by throwing, rolling and dragging. The transportation
shall involve minimum loading/unloading operations. Lifting shall be always by hand and
using rope, wooden beams, in case of small diameter pipes, or using lifting mechanisms or
machines, in case of large diameter pipes.
99
PRE-STRESSED REINFORCED CONCRETE PIPES WITH STEEL JACKETS
(PRCSJ)
1 GENERAL PROVISIONS
Pre-stressed concrete pipes are manufactured as follows: core concrete is poured after
applying pre-stress to longitudinal steel rods of core concrete to be used in pipelines for
conveyance of water with nominal pressure 50 N/cm 2 – 180 N/cm2 and then steam cure is
applied to ensure that core pipe acquires a certain degree of resistance before stress is applied
to it in certain intervals and steel wire is wrapped around it in helical form and then covered
with jacketing concrete.
PRCSJ and fittings designed and manufactured in accordance with AWWA Standards
for Pre-stressed Concrete Pressure Pipes shall be consistent with reference standards issued by
AWWA. If another acceptable standard is recommended, all details, including design,
materials, tests, etc. shall be provided in a comparable set of the reference standards.
The inside diameters of pre-stressed concrete pipe shall be 600, 700, 800, 900, 1000,
1100, 1200, 1400, 1600, 1800, 2000, 2200, 2400 and 2600 mm or another standard diameter
may be proposed by the Contractor and accepted by the Employer.
The Contractor shall be responsible fort he design of all pipes and special fittings.
1.1 References and Standards
The following standards or any other international standard acceptable to the

Employer shall be applied to PRCSJ and fittings to be manufactured under the contract:
American Water Works Association ( AWWA ) C 301-92 Pre-stressed Concrete

Pressure Pipes, Steel Cylindrical Type, for Water and Other Liquids
American Water Works Association ( AWWA ) C 304-92 Design of Pre-stressed

Pressure Pipes
1.2 Classification
Pre-stressed concrete pipes are classified into the following 14 categories depending
on their nominal pressure:
- Nominal pressure(50 N/cm2) , H = 50 m

100
- Nominal pressure(120 N/cm2) , H = 120m.
1.3 Characteristics
1.3.1 External Appearance
The internal and external surfaces of pre-stressed concrete pipes shall be even and
smooth and there shall be no cracks. But, thin capillary cracks may occur on the external
surface when internal pressure is applied. The corners and sides of the pipe ends, especially
their surfaces, which will come into contact with the rubber seal to be used for connecting
pipes shall be smooth and free of any crack, porosity, and burs.
1.3.2 Structural Characteristics
The pipe shall be free of any defects within tolerances specified in respect of the
straightness of internal surface, the smoothness of front face (deviation from carpenter's
square), pressure load on peak point, resistance to internal pressure and waterproofing, water
absorption rate in core concrete and imperviousness of jacketing concrete.
1.4 PRCSJ Design
Pipes and fittings shall be designed in accordance with AWWA C 304-92 and the
requirements of AWWA Manual M9 or other standards acceptable to the Employer.
Detailed drawings of the pipes and special fittings shall be submitted to the Employer
for approval. They shall meet project pressures in respect of all pipes and special fittings.
Pipe designs shall permit internal working pressures and greater pressures resulting from
normal and abnormal operation. It shall be taken into consideration that pipes may be stored
in a warehouse for 12 months or a longer period.
External loading will depend on pipe bedding, filling conditions and excess loads
caused by traffic. The Contractor shall provide necessary tolerances in respect of loads arising
from the construction of the system. The design shall permit loads resulting from special
methods used for constructing trenches.
The design of the pipes and materials used for manufacturing them shall ensure that
they will have sufficient resistance for a minimum life cycle of 50 years.
101
Design calculations shall be submitted to the Employer for approval minimum 2
months before the commencement of pipe production. The Contractor shall furnish the
Employer with concrete mixture designs for its approval 1 month ahead of pipe production.
2 PIPE FITTINGS
Pipe fittings shall be of welded type containing rings with steel ends, which are
integrated with the steel cylinder and assembled by a single internal side seam welding after
the pipe has been placed. Full details of pipe fittings shall be submitted by the Contractor to
the Employer for approval. Assembling method shall also be described fully and submitted to
the Employer for approval.
3 SPECIAL FITTINGS AND PIPES
The Contractor shall submit the designs and drawings of all special hardware and
pipes for approval prior to production. Fittings shall comply with Section 4 of AWWA G 301-
92 or the reference standards defined in Article 1.1. All fittings and connections shall be
protected externally and internally by concrete or cement undercoat.
Outlets and connections shall be either made of special pre-stressed concrete cylinder
pipes or steel plates.
Flanged fittings and borings shall comply with the requirements of ISO 2531 and ISO
7005.
4 FABRICATION
Materials and Steel Jacketed Pre-stressed Reinforced Concrete pipes and special
fittings shall be fabricated in accordance with AWWA C 301-92 or reference standards
defined in Article 1.2.
The Engineer shall, acting as the "Purchaser", at any time be entitled to make
observations and conducting tests in accordance with AWWA C 301-92. Observation and test
reports related to concrete, undercoat steel components, materials and welding shall be
submitted to the Employer for approval and filled out in accordance with the Engineer in
order to facilitate future reference. The Contractor shall mixtures for concrete and undercoat
only if they have been approved by the Employer.
The Contractor shall establish an efficient fabrication control system comprising the
following items:
Production planning and programming,

Design of pipes, special pipes and fittings,
Supply of materials,
Production diagrams,
Quality assurance,
Observation and tests,
Maintenance programs,
Spare part control,
102
Industrial safety procedures,
Records.
5 TYPE OF PIPES AND SPECIAL PARTS
5.1 Type of Pipes
Pre-stressed concrete pipes are divided into two categories depending on their shapes:
 Straight pipes,
 Special parts.
5.2 Special Pipe Parts
Special parts are divided into seven groups depending on their shapes :
 Semi-straight pipes,
 Semi-straight pipes like spigot,
 Semi-straight pipes with a discharge outlet,
 Bends,
 Adaptors,
 Reducing pipes,
 T pipes.
5.3 Welding for Special Fittings Fabrication
Welded sections comprising steel conforming to DIN 17100 or similar steel shall
comply with the requirements provided that they are not below DIN 1910 or an equivalent
standard. Welding shall be fabricated and subjected to testing in accordance with ASME VIII,
DIN 1910 or equivalent standard.
All fittings shall have a straight edge prepared for a profile required for welding. The
sections shall then be mounted and checked prior to welding. Welding and fabrication shall be
conducted so that pressure will be minimized and bending will be prevented. Special care
shall be taken to ensure that there is no bending after the related section is formed.
Each unit shall be fabricated.
Electrodes used shall be of low hydrogen type and meet the requirements related to
carbon steel provided that they are not below TS 5387, DIN 8529 or equivalent standard.
Heated warehouses and furnaces shall be provided for electrodes.
Only experienced and qualified welders with a proven track record shall be employed.
Detailed records showing the name of each welder assigned to a welding work shall be kept
and any welder, who has caused an undesired cases of damage, shall be removed from the
Works until he passes the tests again.
103
Any horizontal blunt weld seams shall be tested radiographically. If required by the
Engineer, blunt weld seams around the circumference of the circle shall be minimum 100 mm
along their length of 1000 mm tested radiographically. Side seams shall be tested by detecting
cracks ultrasonically or by using another approved method.
“International Agency fort he Reference Radiographs of Welding" shall be used as a

source material for interpretation of radiographs and a basis for comparing welding defects.
Black shall be the minimum level for acceptance.
The standards referred to in this section may be replaced by the Employer if another
standard ensuring an equivalent or better quality is provided.
6 PIPELINE ROUTE
Pipelines shall be designed so that the route shown on the Contractor's approved
drawings will be followed. Any change to the route proposed by the Contractor shall be
accepted only if it has been approved by the Employer.
PRCSJ shall be covered by a minimum cover on condition that it is not less than 1.10
m in unchanging inclinations and filled with an approved material.
Pipes shall be placed straightly to the extent practicable. Changes in direction shall be
performed by fabricated bends.
7 SPECIAL FITTINGS TO BE USED IN THE PIPELINE
All special fittings (washer, air valves, bends, Tees, connections to steel pipes, etc.)
shall be designed and fabricated in accordance with data and documents prepared by the
Contractor.
8 PROTECTION AGAINST ABRASION
The Contractor shall be responsible for the design and implementation of measures
against abrasion in order to meet the 50-year project term of the pipes and special fittings
placed in the pipeline.
Within one month after the commencement of the Works and before the
commencement of fabrication the Contractor shall furnish the Employer with full details of
anti-corrosion control measures proposed based on surveys conducted by the Engineer for
approval. They shall include the following:
Atmospheric conditions,
● soil conditions,
The quality of water conveyed through the pipeline,
Interaction with adjacent structures, facilities, services, etc.
Bimetallic connections,
Differential ventilation,
Aerobic and anaerobic bacteria.
104
Abrasion control measures shall comprise the following during fabrication if required:
● Appropriate construction materials,

Abrasion limits,
Protective coating and finishes,
Electric insulation of components.
The Contractor shall submit full details of the anti-abrasion control systems covering
the following items to the Employer for approval if required :
Specification,
References,
Preparation and implementation of instructions,
Repair works,
Test and observation processes,
Quality assurance processes,
Operating and flow processes.
The protective coating proposed by the Contractor in order to protect the external
surfaces of PRCSJ shall be fully conducive to the coating of the pipe by and undercoat during
fabrication. Coating shall ensure full protection of the pipes embedded in difficult soil
conditions.
Coating shall have a thickness allowing the free pores to be covered. Coating shall
provide full protection after 12 months when it is exposed to atmospheric conditions of
unprotected storage in ambient conditions.
Coating shall:
- have sufficient mechanical and adhesive characteristics to withstand maximum expansion of

pipes under maximum pressure without loss of adhesion or a breakage;
- withstand fabrication, handling, transportation, placing and filling without suffering a loss;
- have minimum impermeability for the leakage of humidity and oxygen;
- be fully impervious against chloride and sulfate ions;
- be ineffective against penetration of acid;
- have high dielectric force.
The Contractor shall prove these characteristics by a report to be issued by an

approved independent laboratory.
9 TESTING AND OBSERVATION
ÖBSB shall be tested and observed in accordance with the requirements of AWWA C
301-92.
The welding of fabricated special steel fittings shall be carried out in accordance with
the provisions of "Welding for Fabrication of Special Fittings". Test method shall be
approved by the Engineer. Hydrostatic tests at factory shall not be required for such fittings.
There shall be no visible crack on the surface of the undercoat of the pipes and fittings.
All other cracks shall be repaired or recoated. Areas with minimum damages not exceeding
105
0.05 m2 may be repaired before curing. Larger areas may be stressed and the pipe may be
recoated.
All loose or hollow undercoats shall be rejected. Minor damages at pipe ends or
coating resulting from handling may be repaired.
Repair methods shall be approved by the Employer.
9.1 Cost of Tests
The cost of tests acceptable under international standards shall be paid by the
Contractor at its own expense. Inspections and tests shall be conducted at the factory or a
laboratory of a public agency to be designated by the Employer.
9.2 Technical Inspection
The contractor shall host a two-strong technical delegation representing the Employer
for one week in order to conduct technical inspections about the manufacturing process
provided that all travel and accommodation expenses are borne by the contractor.
10 MARKING
Each straight pipe and special fittings shall be marked from inside and outside in order
to display the following:
Serial number,
Core casting date,
Diameter,
Project pressure class,
The Employer's emblem shall be printed on the external surface of the pipe.
Records shall be kept at the office of the factory of each enumerated unit for all
completed pipes.
11 PACKAGING
Pre-stressed concrete pipes shall be placed on the market without packaging.
12 CONTENT OF OFFER
106
If gaskets are to be offered free of charge, this should be indicated in the offer.
and its parts shall be indicated separately and their detailed technical values shall be provided
in tables.
13.1 Acceptance
The result of tests conducted by using samples taken from a lot delivered shall be
deemed to represent the outcome of the test fort he whole lot.
If 2% of the samples taken for the inspections referred to above are found to be
defective and the Contractor is able to remedy such defects, then the lot in question shall be
accepted conditionally.
13.3 Rejection
tolerances as a result of the tests conducted by using samples, shall be rejected.
14 DELIVERY
As described above, the pipes shall be delivered to such place or pipe storage as will
of 20%.
15 ORDER FORM
16 HANDLING AND STORAGE
All newly coated pipes shall be carried by bedded equipment and slowly in order to
prevent damage or bending. Pipes shall be stored in the form of a row.
Pipes and special fittings shall be stored in the factory until they are taken by the
Contractor. Such storage of pipes shall ensure that they will be used upon fabrication. It shall
be taken into consideration that some pipes may be stored in the pipe storage for a period
longer than 12 months. Pipes and their parts shall be placed vertically on floor and each point
of their base shall come into contact with floor.
107
Stored pipes and special fittings shall be regularly checked by the Contractor in
respect of their shapes. Any visible damage shall be reported to the Engineer and necessary
measures shall be taken in order to remedy such damage. The Contractor shall be liable if any
pipe or special fitting is rejected due to damage at the pipe storage.
Concrete pipes shall be shipped and stored in accordance with the applicable
Technical Specifications and directives set forth in DIN 19695.
Pipes shall be supported by wooden planks or laths not only at the bottom row and
between rows but also from their sides, ends and top in order to prevent any accidental
damage during transportation.
Utmost care shall be taken during the transportation of the pipes, and the pipes shall
not be unloaded, loaded and stacked by throwing, rolling and dragging. The transportation
shall involve minimum loading/unloading operations. The pipes shall be lifted by cranes and
machines using steel ropes and slings. No damage shall be caused to pipe ends and coatings
during loading and unloading.
108
HARD POLYVINYL CHLORIDE (PVC) PIPES
1 General Provisions
PVC pipes shall be used by the Employer for closed system irrigation projects and
drinking water Networks within sites and have the characteristics described hereinafter.
PVC pipes and their special parts, fittings, and other materials shall comply with TS
275-1 EN 1329-1 Standard.
The porosity level of PVC pipes is very low and they look like polished. They are,
therefore, permeate more water than other types of pipes with the same diameter.
PVC pipes are light and can be transported and placed easily. They are resistant to
chemicals (they are affected by few substances). They do not require isolation and conduct
little electricity and are, therefore, not affected by leaked current. Calcerous materials shall
not accumulate inside of pipes (encrustation) and they are flexible. They are not affected by
frost. They can be used in a temperature range between - 40 o C and + 60 o C. It does not
release color, odor or flavor to water. They are used for conveying drinking water, sea water,
industrial water, and waste water.
1.2 Technical Characteristics
The technical characteristics of PVC pipes (resistant to a temperature of 20o C ) are

listed below:
Density : 1.38 – 1.40 gr/cm3

Breaking Stress : 500 – 550 kg/cm2 (tension)
800 kg/cm2 (pressure)
Elongation : 0.08 mm/m C o
Heat Permeability : 0.13 Kcal/mhC o
Elongation at Breaking Point : 10 – 50%
Elastic Module : 30 000 kg/cm2 ’ dir.
The weight of one meter of PVC with a diameter of 80 mm is approximately 3 kg

whereas the weight of a cast-iron pipe with the same diameter is 15 kg. Thus, PVC pipes can
be transported very easily. Water flowing through the pipe is affected by atmospheric
conditions slightly because it does not conduct heat.
PVC pipes are resistant to organic and inorganic acids and alkalis.
There are two types of pipes depending on the area of use:
1. With a thick wall thickness (BD),

2. With a thin wall thickness (B).
Linear coefficient of expansion is high and it must be taken into consideration during
pipe laying process. PVC pipes shall maintain their resistance up to 60 C o and softens above
that temperature (thermo-plastic). They can be processed between 120- 145 C o . Boiling
109
range is 200 – 220 C o . PVC is carbonized without flame because it is not combustible. It is
not affected by corrosion observed inside of the pipe or resulting from soil at temperatures
below 60 C o .
PVC pipes are resistant to frost and water shocks. For example:
60 mm Cast-iron pipe, V = 0.7 m/sn, Shock = 9.3 kg/cm2,
60 mm PVC pipe, V = 0.7 m/sn, Shock = 3.0 kg/cm2 ,
60 mm Polyethylene pipe, V = 0.7 m/sn, Shock = 1.0 kg/cm2 .
1.3 PVC Pipes for Pressure Applications
PVC pipes for pressure applications shall conform to BS 3505. Connections and
fittings to be used shall conform to BS 4346. They shall correspond to the figure given in the
pressure class project.
1.4 PVC Pipes for Non-pressure Applications
PVC pipes for non-pressure applications shall conform to BS 5481. Pipes which are
not covered by BS 5481 shall comply with BS 3506 and pressure class shall be PN 6 Atm.
1.5 General Characteristics
PVC pipes shall be resistant to corrosion arising from ultra-violet rays. A compound
preventing corrosion shall be used for pipe production.
The Contractor shall inform the manufacturer about the atmospheric conditions at the
site and shipment conditions and obtain the manufacturer's proposals about the storage of
PVC materials at the site. Such recommendations, which will be subject to approval by the
Engineer, shall always be taken into consideration.
Flanged fittings and pipe connections except for cases otherwise determined or
approved by the Engineer shall be flexible and covered by a rubber ring or seal as approved
by the Engineer and resist various tests determined according to selected standards. Pipes with
a maximum nominal diameter of 600 mm shall be capable of resisting minimum 1.5 o sagging
while pipes with a minimum nominal diameter of 600 mm shall withstand 0.5 o sagging. All
pipes shall resist tension over 13 mm at initial junction tolerance, which is the distance
measured parallel to the center line of the pipe and it may not be below 6 mm or over 13 mm
or as recommended by the pipe manufacturer and approved by the Engineer. Real junction
tolerance shall be marked on pipes and fittings by using indelible paint before they are laid.
110
2.1 Sampling, Pressure and Impermeability Test
The samples shall be subjected to pressure and waterproofing tests after checking their
thickness.
Pressure at factory test shall be twice the pressure class of the pipe.
2.2 Cost of Tests
Contractor at its sole expense. Inspections and tests shall be conducted at the factory or a
3 MARKING
Symbol of the part’s name (MMA, MMB, F, MMR, MK, etc.)
4 PACKAGING

without breaking.
111
5 DELIVERY, TRANSPORT AND STORAGE OF PIPES
The Contractor or its authorized technical staff shall deliver the pipes to be provided
under the agreement to the site and take necessary precautions against any damage or loss.
All materials shall be loaded on vehicles, transported and unloaded in accordance with
the applicable procedures and recommendations. Hard PVC pipes shall be loaded and
unloaded by two persons, one of whom shall hold the spigot and the other shall hold the other
end without suffering any shock. Maximum care shall be taken during loading, transportation,
unloading and stacking as hard PVC materials can be easily broken due to shocks especially
in temperatures below zero.
Plastic pipes shall be stored so that they are protected against direct sunlight, mud, oil,
paint, gasoline, etc. and other sources of contamination.
Pipes shall be covered by a sheet during storage.
Pipes shall be stacked on even grounds and rows of pipes shall be separated from each
other by straight lathes. Distance between lathes shall range between 1.0 and 1.5 m. There
shall be maximum 10 rows in a stack.
Rubber seals used for inserted spigots shall be stored in cool and dry places and
brought to the site after removing packaging material immediately before their use.
6 CONTENT OF OFFER
the offer.
Calculated gaskets shall be supplied free of charge in excess of 20%
and its parts as well as its gaskets, bolts and nuts shall be indicated separately and their
detailed technical values shall be provided in tables.
examination a sample pipe and connecting piece having the characteristics stated in the offer.
112
7.1 Acceptance
The test representing the condition corresponding to the samples taken from the lot
delivered is compatible with all the requirements at the end of the inspections and tests made
on the pieces and it shall be accepted for the lot it represents.
7.3 Rejection
tolerances as a result of tests conducted by using samples, shall be rejected.
8 DELIVERY
marked.
them.
of 20%.
8.1 Place of Delivery
Pipes and fittings shall be delivered to a route, site, or the Employer's pipe storage to
9 ORDER FORM
113

expense.
also from their sides, ends and to in order to prevent any accidental damage during
transportation.
114
POLYETHYLEN (PE) PIPES
1 General
Polyethylene pipes are used in the following areas:
Underground and surface drinking water systems,

Irrigation water systems,
Wastewater systems,
Sewer discharge systems,
Fire water and cooling water systems,
Sea discharge systems.
Polyethylene pipes to be used for drinking water services shall comply with BS 3284.
Fittings shall be pressure type fittings complying with BS 684, Section 3.
1.1 Scope
These Technical Specifications provides for minimum requirements applicable to

polyethylene pipes and fittings made of polyethylene, which are required for drinking water
and irrigation water systems.
1.2 Standards
PE pipes shall comply with TS 418/1 and ISO 4427 Standards.
1.3 Pipe Specifications
Characteristics of polyethylene pipes:
- The life cycle of pipes is very long (approximately 50 years).

- They are highly resistant to abrasion,
- They can be used in acidic, basic, and salty environments because they are highly
resistant to chemicals.
- It can be easily installed and used because of its light weight.
- There are numerous connection options.
- They can be easily connected within and outside of a channel during installation.
- Minimum quantity of bends are used because pipes are bendable.
- It is perfectly compatible with type of soil and it is not affected by movement of soil.
- There is not leakage from fittings due to perfect welding characteristics.
- They are not affected by sun beams due to catalysts they include.
- They are resistant to shocks.
- Polyethylene pipes can be rotated 360o even without using an bend due to their
mechanical characteristics. The diameter of long coils used for winding pipes may be 18 to 20
times higher than the diameter of the pipe. Thus, the number of head connections is reduced
115
while pace of installation is increased. In addition, installation and labor costs as well as
transportation and storage costs are reduced.
1.4 Raw Materials
The material used for manufacturing polyethylene pipes shall have the following
characteristics:
- The density of the fitting raw material used shall be higher than 930 kg/m 3 according
to ISO 1183 test method.
- The manufacturer shall not add any substance to the raw material in the form of
granules during production of fittings provided that anti-oxidants, ultra-violet ray stabilizers
and pigments may be added to the raw material.
- Raw material used for manufacturing of fitting may be black or blue in color.
- Color shall be distributed homogenously in all sections of fittings.
- Raw materials used and fittings produced shall comply with the regulation on
foodstuff in terms of their physical and toxicological characteristics. In addition, they shall not
release any odor or unpleasant taste to drinking water flowing through them.
- The manufacturer shall furnish the Employer with material certificates, test reports,
etc. related to the raw materials used for fabrication of pipes and fittings.
- Polyethylene (PE) shall be used as raw material for producing fittings. Minimum
required resistance of raw material used shall be (MSR) 8 N/mm2 – 10 N/mm2.
1.5 Technical Specifications
Technical characteristics of polyethylene pipes:
- Pipes shall be laid by butt welding. Electro-fusion welding may be performed if

considered necessary by the Employer.
- The raw materials of pipes and fittings shall not be colored later. In addition, they
shall be purchased from a company with a proven track record.
- The manufacturer shall provide its cost analysis and production, loading, unloading,
and shipment capacity that could be allocated to the Works.
- The Employer's name, standard seal, nominal diameters and pressure shall be printed
on the pipe so that they could be easily read and cannot be erased in accordance with the
Regulation on Foodstuff issued by the Ministry of Health.
- The manufacturer shall provide one year warranty for the pipes and fittings after they
have been laid and tested successfully.
- The Employer may have any test conducted after the pipes and fittings are
manufactured and laid at the site and tested successfully provided that costs incidental to such
tests are borne by the manufacturer.
- Test and tests for the acceptance of pipes and fittings shall be conducted in
accordance with TSE and ISO standards.
- PE pipes and fittings shall be taken over by the Employer in presence of the
manufacturer. Costs arising from inspections shall be paid by the company.
- Pipes and fittings shall comply with the regulation on foodstuff issued by the
Ministry of Health in terms of their physical and toxicological characteristics. The
manufacturer shall furnish the Employer with a hygiene certificate issued by the competent
hygiene agency.
116
- Fittings shall have the same operating pressure as the pipes.
- Fittings may be fabricated by injection / confection method provided that the
manufacturer shall use both fabrication methods in accordance with the applicable standards.
- The manufacturer shall have TSE and ISO 9001 certificates in respect of fittings.
- Fittings of taping tee type shall be used for subscriber connections and such fittings
shall have a collar for electro-fusion (EF) bonding method. The branch end of the fittings
shall permit EF sleeve or coupling sleeve connection. Taping tees shall be capable of being
boiled under pressure and bored.
- There shall be a barcode label containing welding data on EF fittings or it shall be
delivered together with the fittings. Different materials (PE 80, PE 100) or different wall
thicknesses (SDR 11, SDR 17) may be used in EF type connections. But, the same wall
thickness shall be required in case of butt welding.
Requirements about connections :
a - pipes required in the form of coils and fittings shall be connected by using EF
method;
b - Pipes, which cannot be wound in the form of a coil, and fittings shall be connected
by electro-fusion welding in case of pipes up to 180 mm and by butt welding for diameters
equal to or above ø 200 mm (including).
- Components such as T, 90o bend, 45o bend, flange adapter, blind flange, and reducing
pipes shall be connected by using spigot or self EF collar according to the applicable method.
- Sleeves or taping tees shall be suitable for welding main pipelines or the ends of
spigot fittings with EF collars.
The following details shall be marked on the fittings legibly and indelibly:
a - Manufacturer's name,
b - The diameter and pressure of the fitting,
c - Type of polymer,
d - Year of fabrication,
e - Standard size.
- A certificate issued by the related standardization organizations in the country where

the materials were manufactured shall be presented to the Employer in respect of imported
materials.
- Steel flanges shall be in PN class and have suitable holes for bolts compatible with
the flanges of the valves to be used in the pipelines.
- Steel flanges to be used for flange adapters shall be coated by galvanized steel or
another anti-corrosive material depending on the requirements.
1.6 Pipe Jointing Methods
Polyethylene pipes may be jointed by using 4 (four) different methods:
Butt welding.
Electro-fusion welding.
Spigot joints.
Flanged joints.
117
Butt welding and electro-fusion welding are the most commonly used welding
techniques.
1.6.1 Butt Welding
It is carried out by using a special welding machine. The process is based on heating
the pipe fronts to be welded under preset pressure and for a specified period by using a plate
with resistance and bonding surfaces under preset period and time before they are cooled. The
welding process is economic because it does not require additional sleeves.
1.6.1.1 Butt Welding Requirements
The first requirement in butt welding is that materials to be welded shall have the same
parameters. In addition, there shall be a clean working environment, suitable weather
conditions (wind, temperature, humidity, dust, etc.) and that welding shall be carried out by
experienced welders.
1.6.1.2 Butt Welding Procedure
Butt welding shall be carried out in the following sequence:
- Pipes shall be placed in a butt welding machine and affixed firmly by using required
apparatus.
- Shaving apparatus shall be placed on the column shafts of the welding machine and the front
surfaces of the pipes shall be shaved carefully.
- The shaved surfaces shall be on the same axis and their fronts shall come into contact with
each other.
- The front surfaces of pipes shall be separated from each other enough to insert a heating
plate.
- The heating plate shall be applied to the front surfaces under the temperature and pressure
determined according to the technical data of the manufacturer of the welding machine or
calculated by using a formula.
- The heating plate is removed and front surfaces of the pipes shall be pressed against each
other for a certain period and under a certain pressure and temperature.
- Pressure is removed at the end of the period and the pipe shall be cooled.
1.6.2 Electro-fusion Welding
It shall be used where butt welding cannot be applied due to lack of sufficient space.
Special sleeves shall be used for connecting pipes. Special resistance wires shall be placed on
the internal surfaces of the sleeves, which will be welded to the pipe, during fabrication.
Voltage is applied to those wires by an electro-fusion machine and the surface of the PE
sleeve, which will be connected to the pipe, shall be heated to melting temperature and then
welded.
118
1.6.2.1 Electro-fusion Welding Requirements
Only materials of the same type shall be welded in the electro-fusion welding system.
The welding area shall be protected against rain, snow, mud, oil, and similar substances.
Allowable temperature for electro-fusion is between -10o C and +45o C. Electro-fusion
welding shall only be carried out by trained welders.
1.6.2.2 Electro-fusion Welding Steps
- The end of the pipe shall be cut out so that it forms a right angle with its own axis.
- The surface of the pipe to be welded shall be scraped by a scraping apparatus and cleaned
and wiped with alcohol so that there is no oil or stain residue.
- The fitting is attached to the pipe.
- The machine reads the fitting's barcode. If it is not available, the related figures shall be
entered manually.
- The welding machine is operated and the process is completed.
1.6.2.3 Spigot Joints
Steps for spigot joints are as follows:
- An appropriate slippery substance (liquid soap) shall be applied to the seals within the spigot
so that the pipe is attached to the spigot easily and the seals are not damaged during its
insertion. The substance shall also be applied to the section of the pipe to be inserted in the
spigot.
- Insertion depth within the spigot shall be measured and it shall be marked on the pipe.
- The spigot and the pipe shall be placed on the same axis so that their ends are placed
opposite to each other. Pulling apparatus compatible with the diameter of the pipe to be
inserted in the pipe shall be mounted on the top of the pipe and the section with a spigot.
- The pipe and the spigot shall be connected to each other by using the levers of the pulling
apparatus.
- Care shall be taken to ensure that the pipe is pulled when it is on the same axis as the spigot.
Otherwise, the seal may be damaged.
- The insertion process is completed when the insertion depth marked on the pipe reaches the
mouth of the spigot.
- The pipe installed and the pulling apparatus on the spigot shall be disassembled and a new
connection process starts.
1.6.2.4 Flanged Joints
Steps for flanged joints are as follows:
- Metal flange is inserted in the plastic flange.

- The metal flange and the plastic flange is welded to the end of the pipe by butt welding.
- The flanged part (pipe, fitting, hydrant, etc.) shall be placed opposite the flange welded to
the pipe and a rubber seal is placed between those two parts to be connected.
119
- The seals and nuts are inserted through the flanges and tightened in order to connect the
system so that the seal provides waterproofing after the seal is crushed between plastic
flanges.
- Bolts so installed shall be turned several rounds more and the resulting gaps shall be
eliminated. The system is ready for operation after that phase.
2.1 Sampling
The samples shall be subjected to the tests described below.
2.2 Tests
Raw material and pipe tests shall be conducted in accordance with ISO 4427, ISO
4437 and TS EN 12201 standards.
- Design stress of raw material selected for PE pipes is N/mm 2 ’ dir. Pressure tests are
conducted for 100 hours at 20o C, for 65 hours at 80o C and for 1000 hours in accordance with
ISO 4427 and ISO 4437. Thus, the resistance of such raw material and fabricated pipes to
pressure and their useful life is calculated.
- A melted flow index test shall be conducted in accordance with ISO 1133 in order to
determine flow attitudes of the raw material at the corner. It is a test method applied under a
load of 5 kg at 190o C. Melted flow figure so calculated shall not be below 950 kg/m 2
according to TS 1310.
- In order to determine the attitudes of the pipe before it is put into service, tests shall be
conducted in accordance with ISO 527 to determine elongation of raw material at breaking
point (ISO 6256), tensile strength of raw material at the moment of flow (ISO 6259), the
longitudinal coefficient of expansion (ASTM 696) and thus the maximum load to be
supported by the pipe. Disinfecting oven tests may be conducted in accordance with TS 5450
in order to observe expansion and longitudinal changes in the pipe at a certain temperature
and time. Lengthwise change shall not exceed 3%. The quantity of carbon black in the
material is calculated by conducting a test in accordance with ISO 6964. Distribution of
carbon black in material is determined in accordance with ISO/DIS 11420 Standard.
- Butt welding and electro-fusion welding shall be performed in different combinations, which
will be followed by pressure and tensile tests at the welded sections of the pipe (ISO 442 -
ISO 527).
- A density test shall be conducted in accordance with ISO 1183. Density is calculated by the
weight of raw material in air and a special fluid. In addition, the density of the fabricated pipe
is calculated for comparison.
2.2.1 Resistance
The resistance of the polyethylene material shall be computed by using regression

curve extrapolation, which is an international test method. Its long-term hydrostatic strength,
120
which could occur when it is subjected to a 50-year long-term hydrostatic test at 20 o C is
represented by 97.5% lower reliability limit, considered as a property of PE material. Its unit
is megapascal. The level of that unit rounded up in accordance with Renard series is called
MSR (minimum strength required). MSR also indicates PE material classification (DIN EN
ISO 12162).
Wall tension is calculated by dividing MSR by coefficient C. Its unit is Mpa. Wall
tension and safety coefficient factors shall be taken into consideration while calculating
operating pressure of PE pipe systems.
2.2.2 Cost of Tests
Contractor at its sole expense. Inspections and tests shall be conducted at the factory or a
3 MARKING
Symbol of the part’s name
4 PACKAGING

without breaking.
5 DELIVERY, TRANSPORT AND STORAGE OF PIPES
The Contractor or its authorized technical staff shall deliver the pipes to be provided
under the agreement to the site and take necessary precautions against any damage or loss
All materials shall be loaded on vehicles, transported and unloaded in accordance with
the applicable procedures and recommendations.
121
Plastic pipes shall be stored so that they are protected against direct sunlight, mud, oil,
paint, gasoline, etc. and other sources of contamination.
Pipes shall be covered by a sheet during storage.
Pipes shall be stacked on even grounds.
6 CONTENT OF OFFER
the offer.
and its parts as well as its gaskets, bolts and nuts shall be indicated separately and their
detailed technical values shall be provided in tables.
examination a sample pipe and connecting piece having the characteristics stated in the offer.
7.1 Acceptance
The test representing the condition corresponding to the samples taken from the lot
delivered is compatible with all the requirements at the end of the inspections and tests made
on the pieces and it shall be accepted for the lot it represents.
122
7.3 Rejection
tolerances as a result of tests conducted by using samples, shall be rejected.
8 DELIVERY
marked.
them.
Gaskets may be delivered in a separate package in excess of 20%.
8.1 Place of Delivery
Pipes and fittings shall be delivered to a route, site, or the Employer's pipe storage to
9 ORDER FORM

expense.
also from their sides, ends and to in order to prevent any accidental damage during
transportation.
123
1 CATHODIC PROTECTION SYSTEM
1.1 General
For the anode and cathode zones formed throughout the pipeline, it is observed that
there is formation of chemical and electrochemical reactions in anode, whereas there is no
formation of such reactions in cathode. The process in the cathodic protection system is to
give the structure to be protected a cathodic form by artificial means and continuously
maintain this structure in cathodic form by giving energy. In order to maintain the cathodic
form, electric current is given to the pipe by artificial anodes and pipe voltage is shifted in the
negative direction. In that way, since there is no formation of anodic regions, pipeline is
protected against corrosion.
In order to prevent corrosion on the steel pipeline, the potential of the pipe in
unprotected condition shall be shifted to 300 mV in the negative direction.
In order to prevent the pipe laid under ground, the pipe voltage shall be minimum 850
mV in each location or it is sufficient to shift the potential in unprotected condition 300 mV.
In order to significantly reduce the current requirements of steel pipes hot bitumen
absorbed FT-66 glass fiber by melting Blown-Asphalt with 20 x 10 penetration compatible
with TS 4356-4357 and TS 4357 Standards shall be applied on outer surfaces and after
application of two coats it shall provide a thickness of 6.5 mm when measured by caliper.
Lime shall be applied on outer surfaces of the pipes. The inner surfaces of the pipes shall be
coated in accordance with A 24.7. The outer surfaces of pipes shall be inspected with a
detector of 14.5 kV for isolation penetration.
The steel pipeline shall be protected against external corrosion by means of Cathodic
Protection. In the Cathodic Protection System composite anodes coated with titanium oxide
shall be used as auxiliary anodes and an external current supply shall be used.
The responsibilities of the producer and minimum principles to be followed are
determined in this specifications. Except from the principles specified here the current
standard for the issues of project performance, sizing, equipment supply and assembly, taking
into operation and conduction of necessary tests in Turkey is TS 5141, so the related rules and
instructions of this standard shall apply. In addition to the related Turkish Standards, the
concerned international standards on corrosion acceptable to the Employer and Special and
Technical Specifications of Bank of Provinces General Directorate Drinking water Cathodic
Protection Project and Plant Construction can also be used.
124
1.2 Cathodic Protection Surveys and Application Drawings
The route shall be inspected on Site in order to determine the placement points of
anode beds, location of high voltage lines parallel or blocking the line and the most economic
and sufficient location for supplying the cathodic protection system with electricity. During
this inspection the geological conditions, ground characteristics and local conditions shall be
considered and unless otherwise agreed or required, the resistivity shall be measured by
WENNER method for maximum 500 m of intervals. In order the determine the location of
external current electrodes, for the sections where anodes are going to be located,
measurements with sufficient number and frequency shall be conducted within the anode
system placement interval.
The resistivity values determined according to the measurements shall be processes on
a semi-logarithmic diagram throughout the route. The resistivity degree of the ground and
consequently the scope of the cathodic protection system shall be determined according to
this.
The Contractor shall determine the cathodic protection current requirement in addition
to the ground resistivity, conduct the necessary electricity tests for determination of the
conductivity of protective coating of the pipe, enhance the energy supply means for
determination of feeding points that will make isolated flanges to be used for all the structure
and plants throughout the pipeline like discharge, suction, inspection chimney, air chimney,
stream and road passages, fixing masses etc. and shall prepare detailed application drawings
and submit to the approval of the Employer with a report by considering the data obtained
from here.
After completion of the Cathodic Protection Construction Works, the adjustment,
measurement and acceptance tests and document dossiers, operation and maintenance
instructions and guides shall also be accepted in the scope of survey and project.
The following measurement and survey shall be conducted throughout the pipeline at
100 meter intervals.
TS 5141
Measurement and Research: Clause No :
 Ground Electricity Specific Resistance 1.1.1.1
 Ground pH Value 1.1.1.2
 Ground Redox Potential 1.1.1.3
 Pipe / Ground Potential 1.1.1.4
 Sulphate Reducing Bacteria 1.1.1.5
 Underground Water level 1.1.1.6
 Leaking Currents 1.1.1.7
 Pipe Isolation Permeability -
125
The determination of protective current and determination of pipe isolation
conductivity shall be found by tests and calculations. In these tests pipe/ground potential shall
be measured between the pipe by a reference electrode at intervals exceeding 500 meters and
the anodic and cathodic zones shall be detailed in order to determine the limits of minimum
protection criterion.
Measurement and Testing:
The Ground Electrical Specific Resistance measurements shall be in accordance with

TS 4363. For the sections where anodes are going to be located, measurement with sufficient
number and frequency shall be conducted within the designed anode system and placement
interval. The resistivity values determined according to the tests shall be processed on a semi-
logarithmic diagram throughout the route. The aggressiveness degree and the scope of the
Cathodic Protection System to be established shall be determined herein.
Cathodic protection current requirement shall also be determined in addition to ground
resistivity. Accordingly, the locations of the isolated flanges to be used with all structure and
plants like discharge, suction, inspection chimney, air chimney, passage of road and stream,
fixing masses throughout the pipeline, conductivity of the protective coating of the pipe shall
be determined.
The determination of suitable locations for anode beds shall be in accordance with the tests
and the locations of the feeding points and current requirements shall be determined according
to this measurements.
1.3 Preparation of Application Drawings
The calculations shall be made in accordance with the survey data gathered throughout
the pipe route and laboratory findings and the acquired values shall be processed into plans
and tables. The project calculations shall be based on the values of related standards and
specifications. These sources shall be submitted to the Employer if requested. The Contractor
shall proceed the following before project is drawn up:
Necessary measurements for determination of soil specific resistivity
PH control for different soil samples taken from places where ground
demonstrate variation throughout the pipeline route
126
Inspection of pipe blow up for determining the pipe current requirement and
electrical tests if necessary
Investigation of electrical continuity throughout the pipeline, determination of
isolated flange data to be used for all structure and plant like pressure reduce
chamber, line drains, air relief valves, passage of road and stream, fixing
masses, determination of suitable locations for anode beds, research for energy
opportunities for determination of current injection points, the underground
plants close to pipeline and high voltage transmission lines
The followings shall be considered during Project organization
a ) Determination of Cathodic Protection Types
The followings two types of protection method can be applied partially or completely
within the project:
1 . Galvanic Method
2 . External Current Source Method
1 . Galvanic Method:
The pipeline is protected against corrosion by connection of sufficient number of
galvanic anodes manufactured from magnesium, zinc, aluminum or their alloys that are
more electronegative potential than the steel at different locations of the pipeline. The
protective current necessary for the pipe is obtained through dissolving of galvanic anode.
In order to provide the performance of galvanic anode system the following issues shall be
considered.
The galvanic anode beds shall be installed for low resistance places.
The beds shall receive underground water from the base as much as possible,
when determining the locations of the beds this shall be considered. If there is
not any possibility of receiving water from the ground, the anodes shall be
watered from time to time in order to provide efficiency.
The zinc anodes can be successfully used at places where resistance is higher
than 1500 ohm-cm and the magnesium anodes can be used at places where
resistance is higher than this value. However the protective current value
supplied by magnesium anodes decrease to very small values for soils with
specific resistance value between 6000 ohm-cm and 10000 ohm-cm, it is not
an economical method for some cases.
127
In order to reduce the transition resistance of galvanic anode according to the
ground resistance filler materials are used. As the resistance value of the
anode increases the amount of filler material shall be increased.
External Current Source Method:
The protective current required by the pipe is provided through the rectifiers that
transforms the alternating current from the city network to direct current in external current
source method. The negative end of the rectifier is connected to the pipe and the positive end
is connected to the anodes.
The selection of suitable types from them shall be performed by economical analysis
of the whole protection system. (shall be in accordance with TS 5141 Clause 1.1.1.1)
The following issues shall be considered herein:
Current cost
Initial plant cost
Interference effect
Operational and maintenance costs
b ) Cathodic protection criteria (shall be in accordance with TS 5141 Clause 1.1.8)

c ) The resistance of the anode bed shall not pass 1 ohm (as far as possible)
d ) The anticipated anode life shall not be less than 30 years
e ) The determination of cathodic protection resistance requirement
The current requirement of the pipe or pipe part shall be determined in accordance
with tests. The increase in the current requirement due to deformation of isolation by the
passage of time shall be considered in the project.
f ) Electrical Insulations
In order to prevent the cathodic protection current flowing through undesired
installations or to protect from undesired current at the following plants, (isolated) flanges
shall be installed between two pipes. (Application shall be in accordance with TS 5141 Clause
1.1.3)
 Pumping stations and treatment plants
 Current leak zones
 Concrete walls/road passages
 Underwater passages
128
g ) Electrical Contacts
For the seamless pipe joints in order to conduct the Cathodic Protection current,
electrical connection from pipe to pipe shall be in accordance with TS 5141 Clause 1.1.4
h ) The number and installation locations of measurement stations and measurement

boxes, anode beds, Transformer/rectifier units shall be determined by considering the
structure of the land and suitable locations on the pipe route, and with the staff of the
Employer.
The minimum isolation level required from the joint (when pipes are empty) shall be
determined during application project phase. The test pressure of the joints shall be the same
as the water supply pipeline test pressure. Welding, welding inspection, inner and outer
isolation and tensioning shall be in accordance with the pipe specification.
All values for construction of the joints shall be submitted to the approval of the Employer
and the joints shall provide the following:
Construction
Economical analysis
Sizes
Operational and test pressures
Test method
Operational and maintenance guides etc.
When the Works are completed the functionality of the system shall be tested and the test
results shall be submitted to the Employer together with a report.
1.4 Cathodic Protection Life
Cathodic protection life shall be considered as minimum life of all the material and equipment
used for cathodic protection application. However, -except from the failures- it shall be
considered that the anode metal is used up in the cathodic protection system, for that reason
the cathodic protection life shall be taken as the length of the period for consuming the 85%
of the anode in the system. Anode life shall be calculated with the following formula
considering the amount of current from the anode and intensity of the current and the values
given in the project calculations:
129
Anode Life(year) = Anode Mass(kg) x Wearing Factor(0.85) /Intensity of the current
From anode(A) x Wearing of the Anode(kg/A-yıl)
For the cathodic protection projects the cathodic protection life or in other words
anode life shall be at least 15 (fifteen) years.
1.5 Submission of Project to Employer for Approval
The Cathodic Protection Project shall be drawn up by the Contractor and submitted to
the Employer for approval.
1.6 Material and Equipment
1.6.1 Anodes
1.6.1.1 Auxiliary Anodes
1.6.1.2 Galvanic Anode System
1.6.1.3 Magnesium Anodes

The type of the magnesium anode as galvanic anode in the cathodic protection systems
with magnesium anodes shall be determined as 17 lb or 32 lb according to the electrical
specific resistance of the ground from where the pipelines will pass from.
NYY cables (1 x 6 mm2 in cross section and minimum 3 m in length) shall be mounted on
the anodes and a separate cable shall come from each magnesium anode to measurement
box. The length of the cables of the magnesium anodes that will be used individually or in
groups, shall be such that they can be connected to the pipe by shunting from the top of
the measurement box without extension and there shall be a separate cable from each
magnesium anode to the measurement box.
The current carrying conductor placed in the magnesium anodes during casting, shall be
from nervure iron. During casting the surface of the material shall be free from dirt, rust,
oil etc. and other foreign substances.
The mass magnesium used for the manufacturing of the magnesium anodes shall be
99.9% pure. During casting of the magnesium anodes scrap material like previously used
anode or another magnesium alloy shall not be used.
130
It shall be determined by the Employer (by observation) that the anodes are manufactured
from pure material and the anodes shall be sealed by the Employer after casting with a
suitable way. If it is required by the Employer samples can be taken in order to perform
chemical and electrochemical tests.
The chemical composition of the cast magnesium anodes shall be as follows:
Aluminum (Al) . . . . . : 5.3-6.7%
Zinc (Zn) . . . . . . . .. . : 2.5-3.5%
Manganese (Mn) . . . . : 0.15% (minimum)
Silicium (Si) . . . . . . . . : % 0.3 (maximum)
Copper (Cu) . . . . . . . . : 0.05% (maximum)
Nickel (Ni) . . . . . . . . . : 0.03% (maximum)
Iron (Fe) . . . . . . . . . . . : 0.03% (maximum)
Magnesium (Mg) . . . . . : remaining
Aluminum and zinc shall be used for manufacturing the determined chemical
composition of the magnesium anode. The electrochemical characteristics of these
magnesium anodes shall be as follows:
Electrode potential (Ref. Cu/CuSO4 saturated > (-) 1500 mV (in sea water)
Theoretical current capacity (A . hour/kg) = 2200
Anode yield > 50%
The cost of chemical and electrochemical tests shall be at the Contractor’s expense.
1.6.2 External Current Source System
1.6.2.1 Titanium Anodes Coated with Mixed Oxide

The anodes used at external current source system for pipeline protection are named as
current source anode or auxiliary anode. The types and sizes of mixed oxide coated Titanium
anodes, one of the anode type to be used, shall be given in their projects. Deep well anode
channel shall be used inevitably in order to prevent the interference effect at cathodic
protection of pipelines with external current source.
The most economical and longest life anode for deep well anode channel opened in
the ground is mixed oxide coated titanium anodes. The technical specifications of mixed
oxide coated titanium anodes are as follows:
Current intensity in fresh water and ground. . . . . . . : 100 A/m2
Anode mass loss mg/year (maximum) . . . . . . . . : 5
Anode life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 25 years (minimum)
131
Anode sizes . . . . . . . . . . . . . . . . . . . . . . . . . .. . . : 1.6 mm diameter, 50 cm length
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : 4 A
1.6.2.2 Iron-Silicon Anodes

Iron-silicone anode shall be used as auxiliary anode at the pipelines that shall be
protected with external current source cathodic protection system. The iron-silicone anode:
D (head diameter) = 100 mm , d (body diameter) = 75 mm , L (length) = 150 mm and
weight 100 lb. (45 kg). The chemical composition of the auxiliary anodes shall be as follows:
Silicium (Si) . . . . . . : 14-16%

Chrome (Cr) . . . . . . : 4-4.5%
Carbon (C) . . . . . . . : 1% (maximum)
Manganese (Mn) . . . : 1% (maximum)
Iron (Fe) . . . . . . . . . : remaining
The head sections of the iron silicon anodes shall be protected with an isolated
substance. At the head section of the anode, there shall be a connection cable 1 x 10 mm 2
NYY whose connection is completely isolated and that has no contact with the outside. The
surrounding of the connection of the connection cable with the anode and the section in the
anode head shall be isolated with a protolin type hardening material.
Cast iron, ferrosilicon and ferrochrome shall be used for casting of anodes. The
amount of these materials shall be proportional to the chemical composition of the anode. An
adaptor from good quality steel and at least 1 cm in diameter shall be placed in the anode.
Anode cable can be connected to this adaptor. The cast anodes shall be free from cracks. In
order to determine the conformity of these requirements during casting, the Subcontractor
shall inform the Contractor who will then inform the Employer of the location and time of the
casting. If the Employer requires so, after observing the casting in the working place, he can
give order for chemical analysis and electrochemical test of a sample taken from any anode at
the Contractor’s expense.
132
1.6.2.3 Anode Bed Material
1.6.2.4 Galvanic Anode System Anode Bed Material
1.6.2.5 Anode Bed Material for Magnesium Anodes
Component Name: Type A Type B

Jibs (CaSO4 2H2O) % 70-75 25-30
Betonite % 20-25 40-50
Sodium Sulphate(Na2SO4) % 5-6 25-30
Specific electrical resistance (ohm-cm) 50-100 25-50
1.6.2.6 External Current Source System Anode Bed Material
1.6.2.7 Anode Material for Mixed Oxide Coated Titanium Anodes

Mixed oxide coated titanium anodes shall be used by placing in an anode bed material
in order to reduce their electrical resistance and prevent polarization.
Metallurgical coke dust shall be used as anode bed material. The maximum grain
diameter of the coke dust shall be 10 mm and portion passed from no 100 sieve (dust) shall be
less than 5%. The anode bed electrical specific resistance (resistivity) shall not be more than
50 ohm-cm under these conditions.
1.6.2.8 Anode Bed Material for Iron-Silicon Anodes

In order to decrease the electrical resistance of the iron-silicone anodes and prevent
polarization they shall be placed in an anode bed material. Coke dust shall be used as anode
bed material. Caustic lime shall be mixed in coke dust during application at a proportion up to
10%. The maximum grain diameter of the coke dust shall be 10 mm and the portion passed
from no 100 sieve shall be less than 5%. The electrical current of the anode bed filler material
shall not be more than 50 ohm-cm. 200 kg of anode bed filler material shall be used for each
anode.
133
1.6.3 Transformator- Rectifier (T/R) Unit
1.6.3.1 External Current Source System
1.6.3.2 T/R Unit for Mixed Oxide Coated Titanium Anodes

The transformer-rectifier unit shall be air-cooled type. It shall have two panels, one
outer panel and one inner panel. The outer panel shall be external type. The electricity,
electronic equipments and measurement tools shall be mounted on the inner panel.
The inner and outer cabins of the T/R unit shall be manufactured from 3 mm DKP
sheet iron. The outer and inner cabin shall not require any maintenance for 5 years and shall
provide a 10 years of life span according to the atmospheric conditions and the thickness of
paint to be applied on the prepared surface shall provide this condition. For this purpose at
least one coat of anticorrosive primer, two coats of anticorrosive intermediate paint and one
coat of last paint shall be applied on T/R unit.
The paint application shall provide the following characteristics. Initially, zinc
phosphate based epoxy paint with two components (7/1 in proportion) shall be applied on
DKP sheet iron surface coated with electro cadmium. The amount of solid matter in this pain
shall be 66%. Acrylic isocyanate (izosiyanet-automobile paint) based two component paint
shall be applied on this paint applied to form 100 micron dry film thickness. Dry film
thickness of this paint shall be at least 35 micron.
For ventilation of the uninterrupted operating T/R unit all the necessary precautions
shall be taken and panels shall be designed to provide a very good ventilation.
T/R unit shall be uninterruptedly operational under temperatures between -30 o C and
+70o C. The inlet of the transformer shall be 50 V AC – 40 V AC mono phase, and the output
potential of rectifier shall be a required value between 0-50 V DC.
The voltmeter, ammeter and AC counter shall be at least 2% precision and shall be in
a water tight enclosure. The scale of the voltmeter shall be (0-50 V) and the minimum
readable value shall be 2 V. The complete scale of the ammeter shall be 50 A and the
minimum readable value shall be 1 A.
The current received from the T/R unit shall be supplied from continuously changing
voltage grades or grades with at least 60% current yield.
The wires that will be used for the internal connections for the transformer of T/R unit
shall be TSE certified and enameled. Diodes that will be used at the rectifier shall be resistant
to at least 1000 V of reverse current.
134
T/R units shall be servo variac system functionally and shall be capable of automatic
manual state operation with a commutator. In addition to this, the rectifier can be adaptable to
SCADA system with the addition of electronic cards. The Contractor shall demonstrate this
adaptability with one or several rectifiers selected by the Employer. After a sufficient period
following the short circuit condition, T/R unit shall e capable of applying current to the circuit
automatically.
1.6.4 T/R Unit for Iron-Silicon Anodes

The transformer/rectifier unit shall be silicone diode and oil-cooled type. For diodes, if
diodes are to operate under two times of the normal load, a cooling body with sufficient size
shall be used. The reverse potential value of the diodes shall be at least 1000 V and shall be
protected so that it will not retard the excess potential.
T/R Unit shall be uninterruptedly operational under temperatures between -15 o C and
+70o C. The current inlet shall be mono phase and output potential shall be selected between
0-60 V DC. The voltmeter and ammeter shall be at least 2% precision and shall be in a water
tight enclosure. The scale of the voltmeter shall be (0-60 V) and the minimum readable value
shall be 2 V. The complete scale of the ammeter shall be 50 A and the minimum readable
value shall be 1 A.
There shall be AC inlet fuse, inlet phase lamp, paco circuit breaker capable of fine and
simple adjustment of voltage adjustment grades. Paco circuit breakers shall be designed such
that they can adjust the potential grades of 1-5 V at fine adjustment grade and 6, 9, 12, 18, 24
and 48 V at the simple adjustment grade.
The outer cabin of the T/R unit shall be from 2.5 mm DKP sheet iron and the surface
shall be coated with 1 coat of primer and 2 coats of anticorrosive paint resistant to air and sea
conditions.
Oil boiler of the T/R unit shall be in size and volume sufficient for cooling the heat
generated when transformer is operating at full load at a temperature that can rise up to +70 o
C. The oil boiler shall be manufactured from 2.5 mm DKP sheet iron and there shall be an oil
indicator, a thermometer for measurement of oil temperature, filling cover and a oil plug for
discharging the oil. A transformer and diodes mounted on coolers shall be placed in the oil
boiler. The connections in the rectifier panel shall not be effected from the oil temperature and
shall be made with neoprene isolated cables. If requested by the Employer the T/R units shall
be manufactured as air cooled or automatic type.
135
1.6.5 Measurement Boxes
1.6.5.2 Measurement Boxes for Mixed Oxide Coated Titanium Oxide Anodes
The detailed pictures of the measurement boxes shall be given in the project
schematically. There shall be two ends in the measurement box providing the connection
between the pipe and the T/R unit and one end in the measurement box providing the
measurement of the pipe potential. In addition to this there shall be measurement card with
transparent plastic enclosure in the measurement box.
The paint of measurement box shall be in accordance with the paint rules for T/R units
and same materials shall be used. In addition to this, after application the heading sections of
the measurement boxes shall be numbered and pipe distances and pipe kilometer shall be
written on its surface.
1.6.5.3 Measurement Box for Iron – Silicone Anodes

A steel pipe with  150 shall be placed in a reinforced concrete mass in 40 x 40 x 50
cm size and there shall be a cast cover with impulse bolts at two side on the top of the steel
pipe in order to prevent intrusion of dust and humid. The inside of the pipe shall be filled with
bitumen up to polar ends of  20 and a fiber plate shall be placed on the bitumen 3 mm in
thickness such that brass polars can pass through it. The shape of the measurement box and
the number of polars inside of it can be changed by the Employer according to the needs of
usage. A measurement and failure alarm panel shall be placed in the buildings of the pumping
station and when the value falls an audible alarm shall be generated.
1.6.6 Cables
The cables used in the cathodic protection system shall be in NYY type and in
accordance with TS 212. The conductor of the cables to be used at DC contact shall be from
electrolyte cupper, multi wired and single vessel.
2 x 6 mm2 NYY type cable shall be used for 220 V AC feeding of T/R unit.
T/R unit – pipe space and T/R unit – between the anode bed and anode ring cable 1 x
16 mm2 NYY type cable shall be used.
1.6.6.1 Electrical Isolation (Isolated Flange Gasket Set)

At the both ends of the pipeline or valve connections of the branches isolated flanges
shall be placed as shown in its project. For this purpose, the available flanges on the pipeline
136
shall be isolated. The potential difference between the two sides of the isolated flange
(cathodic protected section and cathodic unprotected section) shall be at least 300 mV.
Isolated flange shall consist of thrusts (bolts, nuts), shim and insulating material (neoprene or
rubber).
1.6.7 Production and Mounting
1.6.7.1 Mounting of Anodes
1.6.7.2 Galvanic Anode System
1.6.7.3 Mounting of Galvanic Anodes

Galvanic anodes shall be placed at a distance at least 3 m from the pipeline and at least
2 m of depth. The galvanic anodes shall be placed in the anode bed material of the type and
size determined in the application drawings. Anodes shall be placed as packaged in cloth bags
with anode bed material in standard size. The anodes to be used as packaged shall be kept as
dry during storage. Separate storage of anode bed material shall be dry and under a non-
humid condition.
The galvanic anodes shall be connected to the pipe by shunting with brass plywood
from the top of the measurement boxes. The anodes shall be connected to the pipe so that it
will generate the minimum electrical resistance by termite type welding. If more than one
anodes are used, cable from each anode to the measurement box shall be without extension.
All the cables used for galvanic anodes shall be NYY type TSE certified (TS 212) and shall
be passed through a polyethylene pipe if necessary.
After cable mounting at the connection points of galvanic anodes and the pipe, this
area shall be isolated at a precision such that it will demonstrate a higher resistance than the
pipe coating. During placement of anodes, anode cable shall not be damaged and the cables
whose insulator has been damaged shall be changed.
1.6.7.5 Mounting of Mixed Oxide Coated Titanium Anodes Karma

The deepwell shall be 22 cm in diameter and at depth and size calculated in the project
reports as specified in their projects. There shall be normal caisson pipe at the first 10 meter
section from ground surface and there shall be perforated caisson pipes at deeper sections of
the deep well.
137
There shall be a ventilation and gas discharge pipe ¾ inches in thickness at the middle
of the shaft. Anodes shall be connected to this pipe with plastic clips. The first 10 meter
section from the ground surface of the ventilation and gas discharge pipe is without holes and
deeper sections are with holes. The interval between the holes shall be 15 cm and hole
diameter shall be 5 mm.
These pipes that are placed with the anodes in this way shall be connected to each
other by PVC clips. The connecting element that holds the anodes in this type of connection
shall be resistant to rust.
There shall be no anodes connected for a section of 10 m from each face of the shaft.
The bottom section where anodes are connected shall be filled with metallurgical coke dust of
the suitable grain size or coke dust with 50 ohm-cm maximum resistivity.
The shaft mouth shall be 30 cm higher than the ground surface and a cover with exit
pipe shall be at the pipe end in order to provide gas exit.
1.6.7.6 Mounting of Iron-Silicone Anodes

After opening of the anode bed trench in accordance with the issues and sizes defined
in the application drawings, the iron silicone anodes shall be filled in the trench with 20-25
cm anode bed material, there shall not be any open spaces during this operation. The
connections of anodes in the anode bed shall form a ring and a measurement box with suitable
polar shall be placed at the beginning and end of the anode bed.
The connections of the anodes and ring cable shall be done Thermoweld (Cadweld) by
welding and the connection places shall be isolated with protolin type material.
During installation of the anode bed, particularly combined resistance of the anode bed
shall not have a value higher than 1 ohm.
1.6.8 Mounting of Transformer/Rectifier Unit

Transformer/Rectifier unit shall be seated on reinforced concrete base 60 x 100 x 60
cm in size. At least 40 cm of section of the reinforced concrete shall be above the ground
surface. There shall be pipes for 1 x 16 mm2 NYY cables going to anode bed and pipe in the
reinforced concrete base. Transformer/rectifier unit shall be seated on the reinforced concrete
base as anchored at 4 points. T/R unit outer and inner cabin shall be grounded in accordance
with its method.
The inner cabin that will be mounted in the outer cabin of Transformer / Rectifier unit
shall be easily removable and mountable in case of a failure (both in size and characteristic).
138
The ammeter and voltmeter on the panel of the transformer / rectifier unit shall not
pass the ¼ of the indication scale during transition and first one year of the system.
1.6.9 Mounting of Measurement Boxes
1.6.9.1 Mounting for Galvanic Anode System

Measurement boxes shall be mounted for each anode or anode group.
1.6.9.2 Mounting for External Current Source System

The measurement boxes shall be mounted at the specified numbers:
 One box for current injection points
 One box for at the beginning and the end of anode bed.
 According to the length of the pipeline, 1 box for each 500 meters for short lines
and 1 box for each 1000 meters for long lines.
1.7 Mounting of Cables
When AC cable feeding transformer/rectifier unit, cable between transformer/rectifier

unit and pipe and cable between anode bed and transformer/rectifier unit are placing in the
trench 80 cm in depth, the bottom of the trench and surrounding of the cables shall be covered
with sand and one row of brick shall be laid on them. Thermoweld (Cadweld) Welding shall
be used for contact between all the cables in the system and pipe, and the welding places on
the pipe shall be isolated with a material equivalent of the insulating material of the pipe.
1.8 Excavation and Filling Works
The anode bed excavation shall be in accordance with the size and minimum pipe
bottom depth level calculated in the project according to the determined issues during survey
phase, the filling works shall be layer by layer and the surface shall be brought into the
previous condition.
The top of the pipe shall be opened for the anode bed, cable channels and cable
connection. Particularly when opening and filling the top of the pipe, the pipe and the pipe
coating shall not be damaged. For this purpose, after connection of connection cable with
thermal welding without damaging the pipe and pipe coating, this section shall be isolated
with a material equivalent to the pipe coating. After that, the trench shall be filled with soil
139
free from stone, grass, root, etc. layer by layer at least 20 cm, compacted and the finally the
top surface shall be brought into the previous condition by filling with filler material.
1.9 Interaction with Surrounding Buildings
Negative effects on cathodic protection caused by the possible “interference” due to

other metallic structures and negative effects of the high voltage energy transportation lines
shall be removed and this operation shall be in the additional works scope. All kinds of
negative effects shall be removed.
1.10 Transition and Acceptance
After completion of manufacturing and mounting works of the cathodic protection

system, a committee formed by the Employer, Contractor and Technical Staff shall conduct
the necessary measurements.
1.10.1 Transition and Acceptance of Galvanic Anode System

The measurements after manufacturing and mounting for the galvanic anode system:
1. Pipe / ground potential (mV),
2. Anode / ground potential (mV),
3. System / ground potential (mV),
4. Anode current (mV).
The system / ground potential shall not be less than (-850 mV) potential value against
saturated Cu / CuSO4 reference electrode at each point on the pipe.
If all these conditions are fulfilled the project application shall be accepted and if one
of them are not fulfilled the acceptance shall not proceed. In this case the Contractor shall
perform the necessary corrections and prepare system for the temporary acceptance.
1.10.2 Transition and Acceptance of External Current Source System

The measurement after production and mounting of the external current source system shall
be as follows:
1. Pipe / ground potential
2. Anode bed resistance
3. Current output potential through transformer/rectifier unit
4. The current received from the anode bed.
5. Pipe/ground potential at the current injection point
140
The adequacy of the material and equipment to be used shall be compatible with the
construction and mounting works and the following conditions shall be provided:
a. The pipe/ground potential shall not be less than (-) 850 mV potential value against
Cu / CuSO4saturated reference electrode at each point on the pipe
b. The pipe/ground potential shall not be less than (-) 2 V at the current injection
point to the pipe.
c. Combined anode bed resistance shall not be higher than 1 ohm
d. The current received from the transformer / rectifier unit shall not be less than 90%
of the system current requirement
1.11 Cathodic Protection System Tests
After completion of all the installation works related to the Cathodic Protection
system, potential and current adjustment, measurement and acceptance tests and document
dossiers, operation and maintenance instruction and guides shall be drawn up and submitted
to the Employer. After that, test and inspections shall be conducted for 1 year of warranty
period, and the results shall be evaluated. At the end of this period, all the necessary
precautions to be taken by the Employer shall be performed by the Contractor without any
objection.
Acceptance Tests:
After installation of Cathodic Protection System the acceptance test of the pipeline
shall be as follows:
a. The performance of Cathodic Protection Criteria conformance tests defined in
TS 5141 Clause 1.1.8.1
b. Conformity with the “Operation, Maintenance and Repair Rules” defined in TS
5141 Clause 1.3
c. Performance of tests defined in TS 5141 Clause 2
d. During feeding from current source at one point in the pipeline, the potentials
shall be measured simultaneously at all the Centers. The same potential value shall be
obtained during feeding from other centers.
Finally all the current centers shall be adjusted to an average value in order to achieve the
negative potential given in Clause (a).
141
1.12 Cathodic Protection System Signalization
Purpose of this signalization system is to continuously control of the protection of the

pipeline against corrosion and to decrease the control works at the land by monitoring the
main values of the system from a centre. This centre shall be SCADA centre. All the
necessary technical equipment and the installation shall be performed by the Contractor.
Cathodic Protection System shall be installed with separate control hardware and software in
order not to disturb the other plants operations.
Continuous Test Units:
The followings defined in TS 5141 Clause 1.3: Operation, Maintenance and Repair
Rules, the continuous test units shall be installed and controlled from the SCADA centre :
a. For the galvanic anode cathodic protection:
 Pipe-ground potential,
 Transformer/Rectifier outlet potential,
 Current intensity supplied for the cathodic protection system
b. External Source Cathodic Protection ;
c.
 Closed circuit pipe-ground potential,
 Current intensity received from the anode.

In case these values reach to value that can jeopardize the cathodic protection system,
the alarming audible and illuminated warnings shall inform the operator at the SCADA
centre.
During installation of the continuous test units, all the necessary equipment like
detectors, transducers, continuous reference electrodes that can work at the required
measurement intervals shall be installed in order to provide the signalization in the computer
media.
142
Measurement Stations:
Throughout the pipeline the measurement stations shall be installed to be used for
purposes defined in TS 5141 Clause 1.1.6 and for signalization plants specified in addition to
this.
Size of these measurement stations shall be in accordance with the equipment of it and
its functionality.
The continuous test units and structure of the measurement stations shall be resistant
against external conditions.
1.13 Works after Temporary Acceptance
After temporary acceptance The Contractor shall drawn up a detailed instruction

manual on operation, maintenance and repair of the system. For the period between the
temporary acceptance and final acceptance the necessary measurement and controls shall be
performed by the Contractor periodically (minimum four times in a year) and shall be
submitted to the Employer in a report format. In case there are failures in the system due to
project manufacturing and installation, the repair or corrections of these failures or
remanufacturing and remounting works shall be at the Contractor’s expense.
143
PIPE LAYING WORKS
1 EXCAVATION AND BACKFILLING
The trench excavation Works shall be carried out in accordance with the principles
laid down in the “DSİ Excavation and Filling Works Technical Specifications”.
1.1 Trench Depths
The depth of the pipe trenches shall be specified to be under the frost level. The
minimum trench depth for the drinking water facilities shall be 1.00 m as of the pipe.
1.2 Trench Widths
 The trench widths shall be as follows, whereby (d) is the outside diameter of
the pipe and (b) is the width of the trench;
d ≤ 40 cm
for trenches with slope b= 60 cm
for trenches with revetment b= 60 + 2*5 = 70 cm
If cm  d ≤ 70 cm
For trenches with slope, for trenches with an
inclination less than 60 b = d + 2*20 cm
inclination more than 60 b= d+ 2*35 cm
For trenches with revetment b= d + 2*35+ 2*5 cm
If d  70 cm
inclination less than 60 b = d + 2*45 cm
inclination more than 60 b= d+ 2*60 cm
For trenches with revetment b= d + 2*60+ 2*5 cm
In the case that more than one pipe is laid in the same trench, a distance of 20 cm shall
be left separately between each pipe. This distance shall be as much as the distance indicated
in Cathodic Protection Works to prevent the cathodic protection from being affected for the
steel pipes.
No payment shall be made for any reason whatsoever for the excessive excavation of
the trenches that will be excavated wider and deeper than that the conditions indicated above
and the filling of such trenches shall be carried out by using material that conforms to the
instructions given by the control organization.
The decision as to whether the trenches deeper than 150 cm is constructed with slope
or revetment will be made by taking into consideration the technical and economical issues
144
and no act shall be carried out pertaining to this issue without the prior approval of the
Employer.
The Contractor shall be responsible for the safety of the employees and third persons
at the trench excavations and shall therefore take all necessary security measures.
The Contractor shall construct provisional passages using panels at the trench
excavations over the trench in order to provide the passage for the pedestrians.
The revetment to be constructed for the trench security shall be constructed in

accordance with the principles laid down in the “DSİ Excavation and Filling Works
Technical Specifications”.
1.3 Trench Bottom
The granulated bed material on the trench bottom shall be leveled so that the pipes can
be laid in a straight line.
1.4 Pipe End Pits
Head pits of necessary width and depth shall be excavated in order to easily carry out
the connection of both the pipes with spigot and the welded pipes.
1.5 Road Pavements
Asphalt and concrete road pavements shall be cut with cutting machines at the width
of the trench and the other parts of the pavement shall not be damaged. The sideways shall be
carefully dismounted. The width to be dismounted shall be taken into consideration as the
maximum trench width + 2 x 15 cm. The price for dismounting and repair works exceeding
these dimensions in the pavements shall be assumed by the Contractor.
1.6 Trench Fillings
The trench fillings shall be carried out as explained in the “DSİ Excavation and
Filling Works Technical Specifications” and attention shall be paid that no stones larger
than 3 cm will be present in the material used for the jacketing of the pipes.
1.7 Preparation of Pipes at Trench Side
The pipes shall be carefully placed on the trench side and the necessary measures shall
be taken so that they will not slide and roll.
145
2 LAYING OF CONCRETE PIPES, REINFORCED CONCRETE PIPES AND STEEL
PIPES COATED WITH CONCRETE
2.1 Pipe Laying – General
The contractor shall ensure that the conditions and assumptions used for the static
calculations comply with the actual ground conditions, the excavation method, the trench
cross-section, the compression, the materials, the plant cover, etc., and also document this.
Each pipe shall be carefully cleaned and they shall be checked whether they are
undamaged or not before being laid. The pipes that are damaged or have a visually detectable
flaw shall be rejected by the Control Engineer and they shall be replaced with new ones.
The excavation bottom of the pipe trench and the side walls shall be smooth and there
shall be no juts. The pipes shall be placed in the dry excavation. In the case that the
excavation trench bottom is under the groundwater level, the Contractor shall discharge the
water with the approval of the Control Engineer. Discharging shall be carried on until the
works have been completed or for the period that will be set out by the Control Engineer.
The Contractor shall lay the pipes in the correct alignment and inclination and shall
ensure that the pipes are on a straight line in the horizontal and vertical plane. The pipes of
large diameter shall be pushed with mechanical equipment to the jointing place.
The Contractor shall provide conveniently painted marking posts and lathes at the
places where the pipelines is constructed in the trench provided that the intervals do not
exceed 10 m or at the places specified by the Control Engineer and ensure that the pipes will
be constructed in alignment. The lathes shall have a vertical shoe so that they can stay on the
bottom point. The marking posts shall be placed almost adjacent to the vertical line on the
pipeline and the number of the marking posts placed along the length of the pipeline
constructed with a certain inclination shall under no circumstances be less than 3 (three). The
Control Engineer may bring forward the request, if deemed necessary, for the use of a control
system with laser beams.
The Contractor shall keep the internal part of the pipeline clean and shall make sure
that foreign substances do not enter the pipe as the construction proceeds. Furthermore, the
open ends of the pipes shall be plugged using an appropriate plug after the completion of the
daily work or at the other times where no assembly work is carried out. The Contractor shall
take the necessary measures to prevent the floating of the pipes.
A marking band shall be placed 30 cm over the pipe and cables in the trench and the
canals and similar structures.
2.2 Granulated Material for Pipeline Bed
The granulated material for the pipeline beds shall consist of gravel or broken stones.
The material for the pipes with inside diameter up to 120 cm shall have grain sizes between
20 mm and 5 mm, all of these grains shall pass through 20 mm sieve and maximum 5% of
these grains shall pass through 5 mm sieves.
146
The material for the pipes with inside diameter up to 200 cm shall have grain sizes
between 37.5 mm and 5 mm, all of these grains shall pass through the 37.5 mm sieve and
maximum 45% of the grains shall pass through 20 mm sieve and maximum 20% of the grains
shall pass through 5 mm sieve.
2.3 Laying of Concrete Pipes
The pipes shall be laid in accordance with the conditions laid down in DIN 4033 and
according to the instructions of the manufactures with regard to the factory manufactured
pipes unless a request to the contrary is brought forward by the Control Engineer. The
displacement of the rubber ring will be prevented when the sliding method will be used for
the construction of the joints. The hanger will not be removed before the pipe has been
sufficiently supported after the construction of the joint and before the approval has been
granted by the Control Engineer.
The pipes shall be generally laid in the trench on the granulated material that has been
laid after the execution of the excavation and has been well compressed except for the
situations where the drying of the concrete is necessary. The grain size of this material shall
be within the limits indicated above.
The thickness of the material under the pipe body shall comply with the section of
Filling Works in the “DSİ Excavation and Filling Works Technical Specifications”.
The bed for the pipes that consists of the granular material shall be shaped by
compressing the material laid over the entire width of the trench. Sufficient amount of
material shall be placed in order to place the pipes in the granulated material and to have a
ground at the correct direction and height. Sufficient empty place shall be left for checking
and testing the joints. The Contractor shall ensure that at least three fourth of the pipe is
completely supported. The trench shall be filled in accordance with the “DSİ Excavation and
Filling Works Technical Specifications” after the pipeline has been tested and approved by
the Control Engineer. This filling shall be compressed by using a method approved by the
Control Engineer without inflicting any damage on the pipes and joints.
Apart from the situations where concrete protection is carried out, the Contractor shall not
support the pipes with any material other than granulated material at any stage of the pipe
laying process. Provisional fillings carried out with brick, stone, etc. shall not be permitted.
2.4 Impermeability Barrier for Pipelines with Granulated Cushion
At the places where the pipes is laid with granular bed filling material or backfilling an
impermeability barrier (an impervious barrier designed along the trench to prevent the
underground water) shall be established at the entire trench width and at intervals less than 50
m generally at the middle of the chimney or pressure blocks along the layer or filling depth.
An impermeability barrier shall also be established in the impervious layer, through

which the pipe trenches will pass or in which they will enter, and in the layer, of which the
impermeability is lower than that of the adjacent layer. In such case, the barrier shall be
established at the crossing point of the layer with the trench excavation in order to achieve the
continuity of the impermeability or low permeability of the layer.
147
The impermeability barriers;
Bitumen shall not be used in the canals where thermoplastic pipes are present.
All methods to be applied must be able to achieve the impermeability.
The trench, in which the pipe is laid, shall be coated with an imperviousness material
(clay, bitumen with sand or plastic with a minimum thickness of 1 mm) or shall be placed on
the filling material.
2.5 Pipe Jointing
The Contractor shall ensure that all pipe joints is constructed fully in accordance with
the recommendations of the manufacturer.
The joint rings and gaskets shall be protected against sunlight until the time they are
used. The Contractor shall ensure that the internal part of each pipe or fitting material is clean
before a joint is constructed. The Contractor shall clean the ends of each pipe to be jointed
and prepare these ends to be jointed as necessary. The coatings of all mechanical joints shall
be constructed prior to the assembly.
The Contractor shall only use the proper joint parts that have been indicated in the
specification and supplied from the pipe or fitting manufacturers. All joints shall be
constructed and tightened according to the instructions of the manufacturer.
Special attention shall be paid that the axis of the pipe to be laid establishes a straight
line with the axis of the previously laid pipe. The spigot and socket passing ends shall be
centered to each other.
The following measures shall be taken for the joints carried out with the sliding
method”. A slippery substance that is not acidic shall be applied on the slippery surfaces of
the masculine and feminine sections of the socket end and rubber gasket but attention shall be
paid for the compliance with the recommendations of the manufacturer of the rubber rings
pertaining to the substance to be used. The Contractor shall ensure that the spigot and socket
ends and the rubber ring are completely dry for the joints to be constructed with the “rolling”
of the rubber ring. The rubber ring shall be implemented by preventing the folding when
tension is applied each time before each joint is constructed.
The protective or other kinds of external coatings shall be corrected after the joint has
been constructed and the internal coating and additional protections shall be completed
without any delay in accordance with the specification or the drawings.
148
2.6 Pipes Passing through Structures
The pipes and the external faces of the structure shall be protected with a single piece
C class concrete where the pipes pass through a concrete or a wall unless there is anything to
the contrary in the drawings. This shall extend 30 cm out of the surrounding concrete wall or
structure and shall have a thickness of 30 cm for the pipes, of which the nominal inside
diameter is less than 60 cm, unless there is anything to the contrary in the drawings. This shall
extend 50 cm out of the surrounding concrete wall or structure and shall have a thickness of
50 cm for the pipes, of which the inside diameter is more than 60 cm, unless there is anything
to the contrary in the drawings.
2.7 Connection to Existing Pipes
At the places where it is shown on the drawings that there should be a connection to
the pipeline or where the request for the construction of such connection is brought forward
by the Employer, the Contractor shall open test pits for this purpose if the need arises to
examine such connections at the beginning of the contract in order to set out the likelihood of
such connections and make sure that the material that has been supplied in the scope of the
contract is suitable for the construction of the connections.
The Contractor shall pay attention and make sure that the interruption of the services
in the existing pipelines remains at minimum level and see to it that such connections will be
constructed at the time deemed appropriate by the Employer. Subsequently, the new pipeline
and connection shall be tested with respect to impermeability including the existing adjacent
pipeline section that could have been damaged by the Contractor. The pipes, which will be
determined to be flawed in the test as a result of a damage that has occurred during the
connection act, shall be removed and replaced by the Contractor. The tests shall be repeated
until successful results is achieved.
Additional cleaning and disinfection that will be necessary for the connection shall be carried
out by the Contractor without any need for expenditure on the part of the Employer.
2.8 Test and Cleaning of Pipelines
2.8.1 Pipeline Test– General
The pipelines for the drinking water shall be tested on site as indicated below:
 Test for the straightness of the horizontal and vertical direction,
 Waterproofing test
In the case that the pipeline does not meet the conditions indicated in the
Specification, the Contractor shall do whatever is necessary for the elimination of the
leakages or damages. The Employer shall have the right to request the excavation of the
related sections. The test shall be repeated as soon as the repair work has been completed.
The tests on the pipelines shall be carried out under the surveillance of the Employer.
149
The fittings to be used for temporarily plugging the open places in the pipeline that
will be subject to the test shall be designed to suit the purpose and the connection shall be
made to withstand the indicated test pressure.
The arrangements that will be made for the test on the pipeline shall encompass the
supply of the equipment necessary for removing the air from the pipeline prior to the water
test.
The Contractor shall keep the records of all tests in a book and this book shall be
available for controls. A copy of each page of this book shall be submitted to the Employer.
There shall be a place for the signature of the Employer on each page to confirm that the test
records have been kept on site.
2.8.2 Implementation and Workmanship
The sections to be tested shall be tightly plugged and the air hole system shall be
completed. The Contractor shall supply at any time such request is brought forward by the
Employer all employees, pumps, manometers and the reserves. The staff shall have such
qualifications as are indicated by the Control Engineer. A water gauging device and a
recording manometer for each pump to be used by the Employer as well as an additional
connection installation for this manometer and a control device for dead weight shall be
supplied by the Contractor. The pumps and manometers shall be of the appropriate brand and
art for the work to be carried out and a good maintenance and adjustment shall be carried out.
The pumps and/or manometers shall be subject to the approval of the Employer. All tests shall
be carried out at a time where the Employer is also present.
In the case that leakages or flawed pipe is set out in the joint, the flawed work shall be
specified and corrected or replaced to satisfy the Employer. Provisional repairs or the
implementation of patch combinations shall not be permitted. The complementary test shall
be carried on after the correction has been carried out until satisfactory working conditions are
achieved.
2.9 Cleaning of Pipeline
The Contractor shall keep the internal part of the pipes clean during the assembly and
keep them free of water, dirt, stone, waste and foreign substances. The internal part of the
pipeline shall be completely washed out with water in order to clean the foreign substances
after the laying and jointing works have been completed and the pipes shall be kept in the
same status until they are taken over by the Employer.
150
3 LAYING OF STEEL PIPES AND REINFORCED CONCRETE PIPES WITH
STEEL JACKET
3.1 Welding of Pipeline
The Contractor shall provide all necessary personnel, equipment and materials. The
equipment shall include, but not be limited to:
Welding machines suitable for pipeline welding,

Pre-heating equipment which ensures uniform preheating around the whole
circumference of welding ends,
Post-weld heat treatment equipment,
Internal and external line-up clamps (the external clamp shall be hydraulically
operated),
Protective canopies (or umbrellas and wind shield collars) so that welding can be
carried out even in relatively bad weather,
Weather proof, insulating mats for the internal insulation of girth welds (at least 1.5 x
diameter wide).
The Contractor shall supervise the site, the welders and their work during the entire
working period. For this purpose the Contractor shall use a qualified welding engineer or
alternatively, if accepted by the Employer, an engineer with documented thorough theoretical
knowledge and practical experience in the performance and evaluation of the welding work.
The welding shall be inspected by an independent inspection company engaged by the

Contractor. It is the sole responsibility of the Contractor to document that welding and
welding inspection fulfill all specified requirements.
3.2 Materials
The steel covered by this specifications shall comply with the base metal used for the
pipe manufacturing.
The weld filler metal selected shall give a weld metal matching the base metal
properties as closely as possible. The yield strength of consumables shall neither overmatch
the base material yield strength by more than the level in EN 499, nor shall undermatching be
allowed.
3.3 Welding Methods
Acceptable welding methods are as follows:
Spiral Metal Arc Welding

Gas Tungsten Arc Welding
Melting Core Arc Welding
The use of welding methods other than those listed above is permitted only with the
prior approval of the Employer. Methods may be used in combination if the same
151
combination and sequence of methods have been qualified by the welding procedure
qualification test.
3.4 Welding Procedure Qualification
The Contractor shall submit a detailed report concerning welding procedure

specifications complying with API 1104. All dimensions, all combinations of materials to be
joined and all repair-welding shall be explained in the report. The procedure to be followed is
subject to the approval by the Supervisor.
The Employer may approve the use of already established, sufficiently tested and
documented procedures not more than 2 years old. Transfer of welding procedure
qualification documents from one Contractor to another is not permitted.
For each stage of welding and prior to start of production welding, the Contractor shall
carry out welding of test joints under site conditions following all of the details of the
approved procedure specifications.
The qualification test shall be carried out on steel with the highest specified
minimum yield strength/maximum carbon equivalent which is expected to be covered by the
Welding Procedure Specification. All the results from the procedure qualification
documents shall be submitted to the Employer for approval of welding procedures.
3.5 Qualification of Welders and Welding Operations
Only skilled welders and welding operators who can document qualifications
relevant for pipe welding will be accepted by the Employer. Prior to the performance of
any welding, operators shall qualify for the relevant welding procedures according to API
1104.
The qualification tests are acceptable if they meet the requirements for visual
examination, destructive testing and for radiographic examination as specified in API 1104.
The testing shall be carried out by an approved laboratory.
Welder and welding operator performance test certificates shall be issued and kept on
site during the whole working period. These certificates are only valid for six months after the
last welding.
3.6 Welding Preparation
Material items’ grades, wall thicknesses and pressure ratings shall conform to the
requirements laid down in the applicable drawings and specifications.
Each pipe or component shall be visually inspected to ensure that it has not sustained
any visually determinable damage. Reuse of damaged items shall be resolved in
consultation with the Employer.
152
All requirements for welding preparation contained in the qualified welding
procedure specification shall be strictly adhered to.
3.7 Welding
All welding shall be performed by qualified welders and strictly in accordance with
qualified welding procedures.
Welding shall be suspended by the Contractor when prevailing weather conditions

impair the quality of the work (e.g., airborne moisture, blowing sand, high winds or
lightning).
Straying outside the weld line is not permitted. Should straying outside this area
occur, this shall be brought to the attention of the Control Engineer, who may require any
such damaged section to be repaired or cut out.
Welding chassis connections shall always be positioned in the centre of the joint
during point welding. These shall be mechanically or magnetically connected to the pipe.
Each pass shall be completed around the whole circumference before the next pass is
started. The position of start/stop on subsequent passes shall not be identical.
Upon completion of the point welding, the weld and the pipe surface shall be cleaned
of weld spatter and other deposits, and shall then be wrapped with a dry waterproof
insulating mat to ensure a slow cooling of the weld zone and to give protection against rain.
3.8 Cleaning after Welding
The surface shall be dry and free of oil, grease, soil and concrete residues. All loose
rust and mill scale shall be removed by wire brushing immediately before welding
inspection. On straight pipes, brushing shall be done mechanically using sharp brushes to
avoid polishing of the steel surface. Therefore a stock of readily accessible new brushes is
required.
Welds fabricated with basic finer metals shall be washed with fresh water. Cleaning by
sandblasting to grade Sa 2 is allowed as an alternative.
3.9 Post Weld Heat Treatment

Heat treatment of weld seams shall only be carried out if specified in the approved
welding procedure or where this is indicated in the projects. Heat treatment procedures shall
be approved by the Employer.
153
3.10 Numbering of Weld Seams
Every girth weld shall be numbered by the Contractor in accordance with a system to
be specified by the Control Engineer. This number shall be painted on the pipe coating on
one side of the joint between 0.5 m and 1.0 m from the seam together with the pipe number
to write down in the pipe book.
For each pipeline and each pressure test section, the Contractor shall fill out pre-
printed forms and enter these in a pipe log. As the work progresses, the Contractor shall
submit the pipe log forms to the Control Engineer. Before the start of a pressure test, the
complete pipe log for the section in question shall be handed over to the Control Engineer.
3.11 Coating of Weld seams
The weld seams and their surroundings shall be carefully cleaned upon completion of
all inspection procedures and shall be protected with internal and external coating.
3.12 Closing of Pipe Ends
During welding on a pipeline segment, all open ends of that segment shall be closed
with a plug. When an intervention in the pipeline construction occurs, the Contractor shall
close the open ends of the pipes. The closure shall be tight enough to prevent any entry of
foreign matter into the pipe.
Plugs shall not be fixed by welding or by any other method which damages the pipe.
They shall be securely attached to the pipe and shall remain in place until the pipes are laid.
3.13 Post Weld Process
Heat treatment shall be applied to the pipes welded, and the welding burrs shall be
cleaned. DIN 1626 requirements shall be complied with.
3.14 Tests
The steel pipes with quality specification, which will be used in the construction of the
water supply pipeline and will be subject to special tests, shall be laid and subsequently tested
according to the requirements of this Specifications and its annexes, and specifically to the
TSE, DIN and AWWA standards of relevance to the subject matter, or their equivalents
acceptable to the Employer, whether or not their numbers are shown in this Specifications or
its annexes.
In case that there are any difference between the standards and the requirements of this
Specifications, the Employer shall be free to decide on which will prevail.
154
The works to be carried out on the pipeline shall encompass the following; the
transport and loading/unloading of the pipes, the excavation and backfilling of the trenches
and the joints as well as the excavation and filling works resulting from that, the construction
of the infrastructures, the supply and installation of the special parts and valves, execution of
the head connections as indicated in the specifications and other contract documents and all
other operations necessary for the construction of the pipelines.
3.15 Application
The pipeline shall be specified along the expropriation border with marking posts and
shall be applied to the field together with the curves on the plan.
The distance between the application post shall not exceed 50 m. Piles in sufficient
number shall be rammed in order to indicate the bends. Before starting with the work at any
section of the pipeline, the curve, tangent and other important application piles of the line
shall be attached to the protection piles and this shall be exhibited in the application plan.
3.16 Cleaning of Expropriation Area
The expropriation area of the pipeline shall be cleaned of all trees, bushes, weeds, dirt
and other harmful substances. However, the trees in the expropriation area, the cutting of
which will not be desired by the Control Engineer, shall not be cut.
The material resulting from the clean up shall be in the possession of the Employer
and shall be removed from the work area prior to the end of the contract or in the way as
requested by the Control Engineer.
3.17 Leveling and Trench Excavation
This shall be carried out in accordance with the requirements of the “DSİ Excavation
and Filling Works Technical Specifications”. "
3.18 Use of Excavation Material
The material of good quality obtained from the excavation shall be used for filling
works. The material obtained from trench excavation shall be heaped along the trench at
sufficient distance from the trench not fall into the trench or cause the side walls to collapse
with its weight.
The material that shall be obtained from the excavation and selected for filling shall be
stored at appropriate places.
3.19 Discharge of Water during Construction
155
As long as the work is carried on, the surface or groundwater shall be discharged into
the places where this is necessary and the pump pits and derivation canals shall be filled at the
end of the contract.
3.20 Pipe Trench Filling
The trench filling shall be carried out in such manner and under such conditions as are
indicated in the “DSİ Excavation and Filling Works Technical Specifications”.
The plant soil layer removed at the cultivated areas shall be placed on top of the
filling, equal to the thickness prior to the excavation but in a thickness that will not exceed 30
cm. The plant soil of the excavations shall be stored separately than the other materials at the
places where the plant surface soil is placed again and the plant surface soil is generally
placed at the location, from which it has been taken in the first place.
3.21 Pipe Lowering and Laying
3.21. 1 Examination of Pipes before Laying
The pipes and pipe parts shall be examined before being lowered in the trench, they
shall be cleaned inside and outside and it shall be checked and specified whether or not the
insulation and the pipes have been damaged during the transport and unloading. The damaged
parts of the pipes shall be repaired before lowering in the trenches in accordance with DIN
19630 if any damage or shortcoming is specified at the internal and external insulation.
The pipes shall be examined once again after they have been laid and before filling has
been carried out to check whether or not the insulation layer has been damaged. The damaged
places shall be repaired in accordance with DIN 19630.
The necessary measures shall be taken to ensure that the pipe will not be subject to
shocks or unnecessary tensions during the lowering act. A clearance of at least 20 cm shall be
left from the wall of the trench and the pipe shall be laid as far as possible as a straight line.
The pipe shall be supported along the entire length and shall be sealed as much as possible.
Any section that will be damaged during the lowering shall be pulled up again and
lowered once again after it has been repaired. In case of the occurrence of any damage that
would affect the structural quality of the pipe, the actions shall be carried out as instructed by
the Control engineer.
At the places where there is a danger of floatation for the pipe, the pipe shall be
protected against the raising power with concrete blocks or with anchorage to the robust
ground and the security factor 1.2 shall be obtained against floating. No permission shall be
given for changing the anchorages or any other action that would inflict damage on the
galvanization of the anchorage.
Where possible, the ends of all pipeline sections that have been lowered shall be
closed with waterproof plugs. The Contractor shall be held responsible for keeping the
internal parts of the pipes clean and keeping them free of foreign substances.
156
3.21.2 Lowering of Pipes into Trench
The equipment and tools to be used for lowering the pipes in the trench shall be
suitable for uniform lowering and shall prevent the pipes from striking the side walls and
trench bottom. The issues, which are indicated in DIN 19630 and pertain to the equipment and
tools to be used shall also apply here.
3.21.3 Laying of Steel Pipes
As far as the weld seams can be recognized under the insulation material if pipes with
longitudinal welded pipes is to be used, attention shall be paid that the weld seam will be at
upper one third section of the pipe circumference as far as possible while the pipe is placed in
the trench. The longitudinal and spiral weld seams shall be placed in overlaps at the joints of
the pipes. Attention shall be paid that the weld seam will correspond as far as possible with
the impartial axis at the bends of the pipes welded in longitudinal direction. DIN 19630 shall
apply for these issues.
3.21.4 Minimum and Maximum Soil Cover for Steel Pipes
The pipes shall be laid according to the actual speed and real level indicated in the
project.
The Contractor shall carry out the calculations for the wall thickness of the pipes that
will be used for the purpose of achieving the stabilization under all circumstances by taking
into consideration that the full and partial air gaps in the pipeline will lead to a load in
addition to the loads resulting from the soil, weight, underground water and traffic loads or
that different load situations will result from empty or full pipeline and such calculations shall
be carried out in such way that the Control Engineer will approve them and the costs shall be
assumed by the Contractor. These calculations shall be carried out according to recognized
and documented standards and methods or Application Regulations.
The following values shall be taken as the basis for the air gaps to be applied:
 Drinking Water Pipes : Half air gap,

 Waste Water Pipes : Full air gap.
The Contractor shall be responsible for the execution of the calculation of water goat
and impact tank in order to be able to specify the definite values that will be approved by the
Control Engineer. These calculations shall be carried out according to the recognized and
documented standards and methods or Application Regulations.
The wall thicknesses given in the Special Specifications of the projects or in the
measurements are the minimum thicknesses.
3.22 Bends
157
Unless otherwise specified in the drawings, the pipeline shall be laid in such a way
that it follows the outline of the terrain as closely as possible. The application of bends shall
be limited to sudden changes of direction or inclination. Adjustment to the outline of the
terrain shall, where possible, be made by suitable excavation of the trench, so that the pipe
can follow an elastic trench only. If the Contractor so wishes and has obtained the Control
Engineer’s approval, field bends may be applied. The Contractor shall only use factory made
bends where stated on the drawings. The Contractor shall be responsible for adapting the
bends to its technology as a result of technological reasons.
3.22.1 Elastic Bends
Changes of direction or inclination with elastic deformations - elastic bends - shall be

made in circular arcs with minimum radius as defined in the following table:
Nominal Outside Wall Elastic Bend Minimum

Diameter Diameter Thickness (mm) Radius
(mm) (mm) (mm) (mm)
700 711.2 10.0 1086 1207
700 711.2 12.5 1086 1207
800 812.8 10.0 1241 1379
800 812.8 12.5 1241 1379
900 914.4 12.5 1397 1552
900 914.4 14.2 1397 1552
1000 1016.0 12.5 1552 1724
1000 1016.0 14.2 1552 1724
1000 1016.0 16.0 1552 1724
1200 1220.0 14.2 1863 2070
1200 1220.0 16.0 1863 2070
1400 1420.0 14.2 2169 2410
1400 1420.0 16.0 2169 2410
3.22.2 Field Bends
Changes of direction or inclination which cannot be made with elastic bends shall be
made with field bends that will be produced by the Contractor in accordance with the standard
drawings and longitudinal cross-sections.
Field bends shall be made in the field by bending straight pipe with a suitable bending
machine. Over the whole bent section, these bends shall have a constant radius as shown on
the applicable standard drawings.
For the control of bending radius, the Contractor shall, for each diameter used, use
suitable and well supporting matrices during the bending of the coated pipes of 2.5 m that
are produced according to the specified radius. The bends shall be made in such a way that
no measurable reduction of the wall thickness occurs during bending.
Bending operations may only take place when the coating over the last 12 hours has
had a surface temperature not higher than 40°C measured on the sunlit side. The bending
158
itself may only take place when the surface temperature of the coating is 30°C or less. The
bending machine shall be operated by a skilled person with experience in the production of
field bends.
Precautions to be taken during periods of time where the temperatures specified

above cannot be ensured by usual procedures may be as follows:
Whitewash with suitable paints,

Shielding against direct sunshine,
Water cooling,
Bending operations only to take place in the morning.
For the specific precautions to be applied, the approval of the Control Engineer shall be
obtained.
No wrinkles shall occur in the wall, and the difference between the maximum and
minimum diameters shall at no place exceed 3% of nominal diameter.
Bending in steps shall be made in accordance with the applicable standard drawings.
Pipes shall not be bent closer to the ends than that shown on the standard drawings and no cuts
shall be made closer than 2 m (1.5 m for pipes with nominal diameter D ≤ 300 mm) from the
bent section.
When bending spiral welded pipes, only pipes not containing iron strip ends may be
used. When bending longitudinally welded pipes, the weld seam shall be placed in the
tensile side 30° - 45° from the neutral axis if the weld seam is visible. However, at these
crossings, of which only one has a length that allows the use of two pipes in the opposite
direction, the longitudinal weld seam shall be along the neutral axis. Irrespective of
longitudinally or spiral welded pipes being used at these crossings, the two bends shall be
separated by at least 1.0 m of straight pipe in order to ensure the required inclination of the
pipe.
The Contractor shall maintain a record of all bends constructed, including pipe
number, pipe length, angle of bend and location in the pipeline.
Pipes that are rendered unusable through incorrect bending shall be replaced. Pipe
coating which is damaged during bending shall be repaired by the Contractor .
All bends (the bends in the opposite direction to each other) constructed shall be legibly
paint marked with angle and scope.
3.22.3 Factory Made Bends
Changes of direction or inclination which cannot be made either with elastic bend or
field bends shall be made with factory-made bends supplied by the Contractor.
Factory-made bends shall be made with R = 1.5 × D or 3 × D. When factory-made

bends which are cut in the field, the portion not immediately required shall be marked with its
new angle.
159
3.22.4 Tees and Y's
Tees, crosses, branches, Y's, manifolds, or other fittings that provide means of
dividing or uniting flow in pipelines shall be either factory-made or manufactured at site.
Appropriate reinforcement threads and securing elements shall be provided for the Tees to be
manufactured.
Tees and Y’s shall be reinforced by wrappings or collars as shown on the drawings.
The wrappings and collars shall be designed using the method described in the ASME
Pressurized Vessels Not Contacting with Flame, Section VIII. Design shall, in any case, be
submitted to the Control Engineer for approval.
3.23 Cutting of Pipe Heads
Both ends of each pipe shall be cut in perpendicular direction to the axis. The starting
and end points of the cross-section surface shall not be at different planes. The roughness at
the cross-section surface shall be eliminated. The cutting action shall be carried out with the
machine or device that will be used to suit the characteristics of the material that will be used.
The pipes shall under no circumstances be cut with impact cutters.
The external insulation shall be cut at a distance of 150 mm to the pipe ends and the
internal insulation at a distance of 100 mm and only primer paint shall be applied to these
sections.
All pipe ends shall be wrapped up for protection during both loading and loading and
transport.
3. 23.1 Connection of Pipe Heads
Before starting with the connection of the pipe heads, the materials that could lead to
leakage shall be removed from the connection point of the pipes. Although the compliance
with the essentials, of which the main points have been given below, shall be obligatory while
connecting the pipe heads, the principles that will be given by the manufacturer of the pipe
shall be more important.
Beside the issues that have been indicated, the compliance with the conditions laid
down in DIN 8563 (Quality control and guarantees of welding and welding workmanship)
shall also be requested with regard to the welding works of the pipe heads in the trench.
The welding work shall be stopped in case of bad weather conditions, particularly
when the temperature falls under C. In the case that it will be necessary to continue with the
welding work under such conditions, sample welds shall be performed before carrying out the
actual welding and it will be set out with a report using the results of the additional test that
the weld has the requested characteristics. The issues indicated in DIN 1960 about this are
valid.
The staff to carry out the welding operations shall have a qualification document given
according to DIN 1850 or equivalent standard.
160
The welders that have the requested welder documents shall be engaged by the
Contractor by assigning a number. The necessary contracts must have been concluded so that
the welders will not quit the work during the construction period. After the completion of
each weld, the welder shall substantiate that the weld has been carried out by him by affixing
the number or signature. The Contractor shall keep records in two copies on each welder. One
copy of these records shall be submitted to the Control Engineer. At least the qualification,
identity, place where the weld has been carried out and the quality of the weld shall be
included in these records.
The fact that the welders have a qualification document does not mean that they can
work without control and the Contractor shall engage a qualified employee that will lead each
welding group and control the works.
When the welding type is electric arc type, the welding electrodes shall conform to the
type given in DIN 1913 or shall be at least of equivalent quality.
The pipes shall be centralized before starting with the welding works with a
centralization mechanism and the pipe axes shall be matched.
The body weight between the pipe welding mouths shall be kept as small as possible.
The weld seam shape shall be set out according to DIN 2559 (the weld seam preparation; the
standard on the shape of the weld mouths).
Any and all operations to be carried out on the weld seam shall be carried out while
the seam is red. The weld seams shall be checked with x-ray in accordance with the principles
laid down in DIN 54111 unless there is a statement to the contrary by the Control Engineer. In
the case that workers must work within the pipe, pipe ventilation equipment shall be supplied.
3. 24 Other Jointing Methods
3.24.1 Threads
Steel pipes with nominal diameters up to 150 mm (150 mm inclusive) may be

threaded at both ends and provided with a detachable screwed coupling attached to one end.
Couplings shall have a minimum length of 44% of the pipe diameter, plus 30 mm, and shall
have parallel threads. Pipe ends shall be provided with conical threads. Coupling bodies shall
be made from similar material to that of the pipes.
3.24.2 Flanged Joints
Where flanges are required, they shall be forgings or made from steel plate having
the same characteristics as the pipe material. Flanges shall be weld-on type and drilled
according to NP 10 or NP16.
Bolts and nuts shall be manufactured as specified for ductile iron pipes.
161
3. 25 Pipeline Tests
3.25.1 Hydrostatic and Impermeability Test of Completed Pipeline
Pipeline Test:
The completed parts of the pipeline shall be subject to hydrostatic and impermeability
tests. All repair and pipe replacement works shall be carried out to achieve the impermeability
after the test and the test shall be repeated until a successful result can be obtained. The water
that will be used for the hydrostatic test and remains in the pipe shall not be discharged until
the Control Engineer gives an instruction to the contrary.
3.25.2 Pressure Test
Filling of the pipeline with water shall be carried out in accordance with DIN 4279.
The additional amount of water to keep the pressure at the desired level shall be
specified in accordance with DIN 4279.
The pressure to be applied at the tests shall comply with DIN 4279.
The temperature of the air and water shall be measured according to DIN 7279, which
will then be recorded in the table given in the standard.
Lengths of the pipeline to be tested shall be specified according to DIN 4279.
3.25.3 Tests
The test pressure shall be applied according to the principles laid down in DIN 4279.
The implementation period of the test pressure shall be specified according to the
principles laid down in DIN 5279.
The test pressure shall be applied according to the principles laid down in DIN 4279.
The test pressure shall be at least 10 kg/cm2.
The implementation period of the pressure shall comply with the principles laid down
in DIN 4279.
The insulation layer shall be tested according to DIN 19630 or equivalent standards.
According to the principles laid down in DIN 4279, the weld seams shall be subject to
test using air prior to the implementation of the hydrostatic test. The test pressure to be
applied shall be 2 Atm.
162
3.25.4 Cleaning of Pipeline
After the completion of the pipeline, particularly the places of the pipes and fittings
that are in contact with water shall be cleaned and the foreign substances shall be removed.
All valves and movable connections shall be cleaned and lubricated, and in operation.
3.25.5 Welding Inspection
Examination shall be performed according to this specifications and the following

codes and standards.
Radiographic examination according to ISO 1106, Part 3. Practice for
Radiographic Examination of Fusion Welded Joints. Fusion Welded Circumferential Joints in
Steel Pipes of up to 50 mm Wall Thickness,
Ultrasonic examination: ASME Boiler and Pressure Vessel Code, Section V, Non-
destructive Examination, Article 6, Ultrasonic Examination Methods for Materials
and Fabrication.
Magnetic particle examination : ASME Boiler and Pressure Vessel Code, Section V,
Non-destructive Examination, Article 7, Magnetic Particle Examination,
Liquid penetrant examination : ISO 3452, Non-destructive Testing, Penetrant
Inspection, General Principles,
Visual examination: ASME Boiler and Pressure Vessel Code, Section V, Non-
destructive Examination, Article 9, Visual Examination,
Hardness measurement: ASTME 110, Standard Test Method for Indentation
Hardness of Metallic Materials by Portable Hardness Testers.
The Contractor shall engage a qualified independent inspection company which

shall perform, evaluate and document all welding inspection. The inspection company shall
be approved by the Control Engineer.
All non-destructive examination shall be performed according to a written procedure.

The procedure shall conform to the requirements of the adequate method standard and this
specifications. Procedures shall be submitted to the Control Engineer for approval and shall
be qualified to the satisfaction of the Control Engineer.
3.25.6 Scope of Examination
All welds shall be 100% visually examined
Guarantee welds (welds which will not be pressure tested) and tie-in welds shall be
examined by radiography and be 100% re-examined.
Ultrasonic examination may substitute radiography where radiographic examination is

impractical and may be used as general back-up for radiography in case of
interpretation/verification problems.
Socket welds and branch connection welds which are not radiographed shall be
examined by magnetic particle or penetrant methods to the extent stated for butt welds.
163
Where spot examination is required in subsequent sections, the welds shall be selected
to ensure that the work of each welder and each welding procedure is included.
If at the end of the spot examination a defect is found out, three preceding and three
subsequent welds shall be examined.
If five or more subsequent welds of one welder show defects, all welds of this
particular welder shall be additionally examined.
All butt welds in pressurized systems with design pressure >16 bar shall be examined
by 100% radiography.
At least 10% of other butt welds shall be examined by radiography along their entire
circumference as described above. The Control Engineer may require a more extensive
examination.
3.25.7 Production Tests
The Control Engineer shall be entitled to select a number of seams for destructive
testing.
The Contractor shall be responsible for cutting out the seams, opening the pipe ends
and rewelding the joint.
The destructive tests shall, unless otherwise agreed, be made in accordance with the
requirements in the respective general welding specifications covering qualification tests for
welding procedures.
The Employer shall bear the cost of these tests if the welds are proved to be
acceptable. However, if it turns out that the seam does not comply with all the requirements,
the Contractor itself shall bear the costs. In this case, the Control Engineer may insist on an
additional seam being tested, and the costs of the testing and renewal of this seam shall be
paid by the Contractor, irrespective of the results. If this seam does not comply with the
requirements, the control may be further extended at the Contractor's expense.
The extent of any such supplementary inspection work shall be decided by the Control
Engineer with the aim of establishing in a satisfactory manner whether the welding work
complies with the requirements or not.
If any change of staff takes place during the course of the welding work, this could
influence the quality of the weld seams. In this case, the Control Engineer may require a new
seam to be destructively tested at the Contractor's expense.
164
4 LAYING OF ASBESTOS CEMENT PIPES
4.1 Pipe Laying
Pipes should be strung longitudinally on the side of trench ready for getting down. But
before, bring them down. They should be checked carefully for possible cracks and crushes
during transportation. It is not always possible to see all cracks. In order to determine them,
pipe should be thoroughly examined and suspicious places should be wetted by pouring
water. If there is a crack at wetted place, it appears immediately.
Defective pipes can be used by cutting defective parts. Cutting work can be performed
by using cutting apparatus.
Pipes shall be lowered into trench carefully by using hand, rope, slope platform and
mechanical equipment, crane and other equipments on bigger ones, after it is satisfied that
they are undamaged.
The following procedures shall be performed on big diameter pipes to be lowered into
a trench with the help of a tripod, crane or excavator:
1 - Two wooden beams are placed on the trench temporarily.

2 - Pipe is rolled over these wooden beams and brought at the line with middle axis of the
trench and a wire or hemp rope is wrapped around it.
3 - After the pipe is raised a little, wooden beams under pipes are removed and pipes are
lowered down to their places in the trench.
Before a pipe lowered into a trench is connected with the adjacent pipe, its heads and
additional parts shall be cleaned thoroughly and shall be checked again for its solidity.
Afterwards, pipe head shall be ready for attaching to other pipe. For this purpose
bottom of the pipe shall be fed by some additional amount of sand or fine soil, pipe ends shall
be aligned and corrected as required, but any hard materials such as stones or wood won’t be
placed under the pipe definitely. Then accessory part shall be attached accordingly.
4.2 Deviation from Axis
Asbestos cement pipes may be laid deviating from their axis due to the elasticity of
joints. Axis deviation at turning passages won’t exceed 5 o. A smaller value shall be used in
pipes with a diameter greater than 100 mm. Medium-size springs can be turned without using
bends due to this feature.
165
The table below gives the radius of smallest arches (curves) that can be turned in case
a deviation angle of 5o and shows how much pipe ends will deviate from each other is shown.
Pipe length (m)

0.30 1 2 3 4 5
Radius of the smallest curve that may
be turned (m) 3.5 11.5 23 34.4 46 53.7
Discrepancy of one pipe from the
other (cm) 2.7 8.7 17.4 26.1 34.9 43.6
Sometimes pipes need to be cut in short lengths for performing these types of turns
and this is very easy with asbestos cement pipes.
Pipes passed into with complete axis and then desired deviation obtained by pulling
free end towards one side. Outer part of a trench should be excavated a little larger at turning
points for providing this.
4.3 Trench Width
Trench base shall be such that maximum 20 cm for each will remain on both sides for
pipes with diameters up to 20 cm (including 20 cm) and 60 cm width, as well as larger
diameter pipes. In case there is more than one pipe in the same trench, maximum 20 cm
distance shall be left between two pipes.
Trench excavations are performed according to the requirements of the "DSİ

Excavation and Filling Works Technical Specifications".
4.4 Trench Fillings
Trench fillings are performed according to the requirements of the "DSİ Excavation
and Filling Works Technical Specifications.
4.5 Acceptance Test of Laid Pipes
Objective for subjecting laid pipes to water tests is to determine if heads are made well
and any failure occurred on pipes due to ignorance and accidents during shipment, storage,
lowering into trench and connecting heads of pipes and special parts.
This test performed after pipe lay out shall generally be performed on 500 m parts of
pipeline. This distance shall be determined by Control Engineer according to its place
depending on land condition and slope.
The following issues should be provided before test:
a ) Conditions of adjustment masses on the line and their resistance against forces that will
appear during test.
166
b ) Pipes shall be partially filled over their top so as to their heads will remain open at their
middle parts, complying with principles of “Filling Pipe Trench” and therefore movement of
the line on vertical and horizontal plane shall be prevented with the influence of forces formed
during test. Bottom and surrounding of heads shall be carefully filled after pressure test.
Because small diameter pipes are light, they move more easily under any pressure and
therefore more filling should be done at places where these are laid. Because pipe heads will
move with movement of pipes, this won’t be permitted definitely.
c ) They shall be supported accordingly in order that plugs inserted at both ends of the line
don’t rush and come out.
After pipeline is filled with water completely, it is allowed for some time both for their
air exit from suction cups and they absorb as much water as pipes can absorb. Asbestos
cement pipes absorb water in negligible amounts of water (10% of pipe weight). Therefore
test should be started only after pipes absorbed as much water as they can. In order to obtain a
healthy result, pipe shall be filled at least 24 hours before, kept under working pressure and
test shall be made after this period.
Test pump shall be placed under the pipeline and its pressure shall be gradually
increased to corresponding working pressure by 1 kg/cm 2 per minute (this pressure is half of
the factory test pressure). This limit is the first stage of pressure test. At this first stage,
pipeline under pressure shall be checked thoroughly and it shall be looked at if there are any
defective pipes and special parts and if heads are generally made well, and by this way a first
elimination shall be performed and faults shall be corrected.
1.5 times of working pressure shall be taken as test pressure, but a value found this
way shall never be less than the test pressure given in the table below.
Pressure Test Evaluation Table

Maximum Acceptable (nominal) Pressure Value of Pressure Test Value to be applied
Pipe Used that is subject to Tests (kg/cm2) (kg/cm2)
2.5 3.5
5 7.5
7.5 11.0
10 15.0
12.5 18.0
15 22.5
17.5 26.0
Manometer shall be attached on lower end of pipeline part being tested, it shall be
checked if smaller pressure to be formed at upper end is less than the corresponding test
pressure for that part and test distance shall be shortened if needed.
Pipeline is kept under test pressure such that it will be sufficient for formation of
leakages at defects, cracks and heads and for analyzing every point. This time depends on
appreciation of Control Engineer and cannot be shorter than half an hour for a distance of 500
m.
A slight dampening may be seen at first 15 – 20 cm part adjacent to heads. Such

dampening may be consisted of small amount of water going from end of the pipe and oozing
(leaking) under the upper layer of pipe. This situation can be observed in asbestos cement
167
pipes. This dampening completely disappears after 4 – 5 days of operation. But if dampening
occurs too much, head shall be replaced or corrected.
After the pressure test resulted positively, trench is filled in a suitable way and the line
is subjected to a pressure 20% more than working pressure, and pipe, special part, fittings
(including fountains) are subjected to last test. IF there is any failure, The Contractor is
responsible for correcting them. Test is continued until no deficiency is left.
5 LAYING OF CAST-IRON DUCTILE PIPES
5.1 Straightening and Cutting of Pipes
Spigot ends of pipes that cannot be elevated or lowered smoothly become flattened
and may prevent correct mounting. Such flattening may be recovered with special stretching
equipments depending on approval of Control Engineer.
Pipes shall be cut vertical to their axis. It is recommended to use circular blade cutters
in cutting procedure. For attaching accessory part well, care should be given for eliminating
all roughness and smoothing the thread, should be avoided to damage elastomer jointing ring.
5.2 Trench Excavation
Trenches shall be excavated to the width, depth, alignments and elevations shown on
the drawings and in accordance with the requirements of "DSİ Excavation and Filling
Works Technical Specifications". Soil filling thickness over the pipeline should be
minimum 1 m and shouldn’t exceed thicknesses given below:
Maximum Thickness of Soil Cover (m)

Nominal Diameter
(mm) With truck load Without truck load
500 5.49 5.36
600 5.30 5.16
700 5.16 5.00
800 5.06 4.90
900 4.97 4.80
1000 4.76 4.58
1100 4.61 4.42
1200 4.48 4.28
168
5.3 Bedding of Pipes
All hard masses and big stones at the base of the trench shall be cleaned. Channel
material shall be from clean sand. Channel material shall go down to minimum 100 mm depth
from lower point of the pipe, when angle of pipe arch remaining inside the channel is 60o:
Nominal Diameter (mm) Anchorage Thickness (mm)

100 150
200 150
300 150
400 150
500 200
600 200
700 200
800 200
900 200
1000 250
1200 250
5.4 Laying and Jointing of Pipes
The Contractor shall carefully check and clean the pipe for ensuring that the pipe is
free of foreign materials, before lowering pipes down to the trench.
In order to provide elevations shown in drawings, smoothing and altitude of the pipe
should be checked by a surveyor level and leveling rod. Minimum slope should be 1 mm per
meter of pipe. It won’t be permitted the slope to be zero.
The Contractor shall provide that inside of pipes are free of water, soil, stones and
other foreign materials during lay out process. At the end of daily works or at other times
when a break is given to laying pipes, open ends of pipes shall be closed with a suitable cap.
The contractor shall take the required precautions for pipes not float.
Pipes shall be laid on a smooth alignment both at vertical and horizontal directions.
Provided that it makes an angle less than 11.25 o, direction of pipes shall be changed after one
or more joints are made if any replacement is required. Deviation angle at each joint depends
on nominal diameter and maximum values are given below:
Nominal Diameter (mm) Maximum Deviation Angle ( o )

100 – 150 5
200 – 300 4
350 – 500 3
600 – 700 2
800 – 1200 1.5
Change of direction won’t be permitted on clamped joints.
169
General Pipe Jointing
Though general pipe jointing depending on the type of joint, basic conditions are the
following.
General cleaning,
Putting on components to their correct places,
Settlement of spigot into the socket correctly,
Obeying Manufacturer’s mounting instructions strictly.
The Contractor shall be responsible for providing required copies of these instructions.
Because of elastic structure of ductile iron material, socket with washer used and
behavior of connection as a joint provides high functional safety. Washers are used in all
connections of ductile pipes with socket. As the pressure inside the pipe increases,
impermeability of the washer also increases. As a result of axial deviations on the line, washer
maintains its impermeability.
General pipe jointing is as follows; spigot end of pipe T2 to be laid down shall be
inserted such that it would completely settle into socket end of T1 pipe. For that:
It is checked if spigot end of pipe T2 threaded correctly.

By using wire brush or a piece of cloth if needed:
 - Inside the socket of pipe T1 and especially the place where washer settles,
 - Spigot of pipe T2 to be attached and
 - Seal is cleaned.
Cheek of seal is inserted into pipe T1 such that they extend towards bottom of socket.
It is checked if it is settled in a correct and uniform way.
Normal joint depth is marked on both sides of pipe over the spigot of pipe T2.
Pipe T2 is brought down into trench by crane. Spigot is kept about 400 mm near the
socket of pipe T1.
Spigot of pipe T2 is inserted into socket of pipe T1 up to washer level. Two events can
be observed here:
 - Pipe is inserted correctly and mounting can continue or

 - Spigot of pipe T2 flattened and may not allow forming a joint. In this case the
pipe need to be straightened.

With lubricating paste:
 - Inner part of seal is coated,

 - Spigot of pipe T2 is coated until 25 mm remains to two marks for determining
socket depth.
170
For settling into its place:
 - two hangs in loop form behind the socket ring of pipe T1, and
 - Two tripore clamps are required.
Two workers put on tripore clamps to hanger loops and socket end of pipe T2 to be
laid by using a hook. The worker who will mount the pipe takes his position in the trench.
Spigot of pipe T2 is brought to the socket of pipe T1 .
It is checked if two pipes are at the same line. If needed, adjustment is performed via a
crane and tripore clamps.
Process of jointing two pipes is performed. The worker mounting the pipe and his
assistant adjust their movements in coordination with each other.
Spigot of pipe T2 is inserted into the socket of pipe T1 until border of the socket
reaches to marks. It is important that no metal is present between pipes, in order that joint has
a certain elasticity.
Tripore clamps are loosened.
It is checked by a scanning device if washer settled into its place correctly.
Note: Excavator shouldn’t be used for driving pipe T2 into the socket of pipe T1.
When this stage has reached, if there is a change of direction shown in pipeline
location plan, this angulation is given by adjusting pipe T2 which is still hanged on the hook
of the crane.
For maintaining pipes in this position, reinforcement is performed by inserting a

backfilling material without stones under them.
Pipe is settled on the bottom of the trench.
5.5 Fixing Masses
Forces applied by the fluid flowing through the pipe or appearing during pressure tests
may be very high. Fixing masses should be used at pressure points for balancing these
pressures:
Points where there are route changes (angular deviation) or diameter changes,
Points opening to branching (Tees),
Pipe ends closed permanently or temporarily during testing that part of pipeline (blunt
flanges).
Trench filling shall absorb this pressure in small curves provided by adjusting pipe
joints.
171
There is no need for additional supports when clamped joints are used. The Contractor
shall perform fixing masses at all points indicated above. Fixing masses shall be produced
from Class C reinforced concrete or Class D concrete without iron in dimension obtained as a
result of calculation. Leaning blocks shall extend from fitting to intact soil level, its fitting
shall be made accordingly and they shall be placed such that all joints could be reached for
repair if otherwise wasn’t shown in drawings. No pressure shall be applied until concrete
solidifies.
5.6 Retaining Wall
Pipes may slide in the following conditions on lines laid slope:
If pipe passes through a shaft, in case slope is 20%,

In case slope is 25% on underground pipes,
Two solutions can be offered in this situation:
- Anchoring pipeline by anchorage bolts fixed on concrete clocks located just behind
of sockets (sockets normally faces source direction),
- Use of clamped joints for not making anchorage at all joints of pipeline.
The Contractor shall construct a retaining wall as shown in drawings or will be

clamped joints. Concrete to be used will be Class C reinforced concrete. Concrete won’t be
subjected to any load until it solidifies.
5.7 Clamped Joints
Clamped joints:
On areas where a lot of lines pass underground, on big urban regions, on industrial
networks, etc. ,
On low-resistant grounds where massive concrete pressure blocks are needed,
Underway of rivers, brooks and streams,
On shafts.
Clamped joints prevents movement (dislodging) of joint from its place. Here, a metal
clamped ring prevents longitudinal movement of joint and connected pipe and fittings. This
ring has a rectangular cross-section with an angular edge and is cut horizontally with a saw. It
is molded as to it has an indent where ring settles in the socket. A slight conical settlement
surface of the ring which forms a radial force provides that the socket settles in this indent and
becomes stable. The joint prepared this way don’t move at even very high pressures.
Clamped joints shall be used at places shown in drawings or requested by Control

Engineer.
172
5.8 Filling around Pipes
Selective Filling:
Backfilling procedure shall commence with laying material around the pipe up to 200 mm
height from upper part of the pipe.
Material to be laid around pipes shall be in type as per sand or gravel used for making
bearing. Material shall be compacted by using hand hammer for obtaining optimum intensity.
Concrete Channel Filling:

If a concrete protection is to be constructed on pipelines, Control Engine may request a Class
D plain concrete layer complying with the following conditions to be installed:
PLAIN CONCRETE PIPE INNER DIAMETER (mm)

DETAILS < 600 601 - 900 901 – 1200
Minimum plain concrete
thickness (mm) 75 75 75
Minimum plain concrete
extension at both borders 150 150 230
of pipe body (mm)
Minimum distance
between plain concrete and 150 150 230
pipe body (mm)
Minimum distance
between plain concrete and 25 25 25
lower part of pipe socket
(mm)
Before pipes are installed, plain concrete will solidify and washed thoroughly.
Before concreting pipeline, it shall be provided by Control Engineer that the pipeline
is in desired length in order to lay out pipes correctly and filling is compacted accordingly.
Pipes having inner diameter of 1200 mm or less shall be settled strongly on precast
concrete blocks and they shall be sealed from these blocks with a filling material made of
saturated soft plywood with 2,5 cm thickness. After pipeline is tested by the Contractor and
approved by the Employer, concrete shall be washed thoroughly, until a suitable profile is
obtained for a desired position and type in order that Class C concrete shall be placed
carefully and compacted and joints aren’t damaged.
Concrete protection shall be placed all along the length of trench and won’t be shorter
than 15 cm at both sides of pipe body. If excavation supports are performed, a suitable cover
shall be laid on that support before pouring concrete in order to make elevation of them easier.
On spigot and socket pipes with flexible joints, concrete protection shall be cut at each
joint on the border of socket as a vertical plane with a plywood band in a given thickness or
another material approved by the Employer.
PIPE INNER DIAMETER (mm) PLYWOOD THICKNESS (mm)

300 or less 12
301 to 600 (incl. 600) 24
601 to 1200 (incl.1200 ) 36
173
If two or more pipeline is to be laid down in the same trench, joints shall face each
other at points where concrete filling interrupted on a pipeline constructed with longest pipes,
and joining of lines constructed with shorter pipes shall be surrounded by concrete.
5.9 Backfilling
The remaining part of trench shall be filled with an approved selected backfilling
material complying with "DSİ Excavation and Filling Works Technical Specifications".
5.10 Equipment
The nominal working pressure of the valves shall be 16 bar.
The nominal working pressure of the fittings and other equipment shall be 16 bar.
Coating
Coating of the valves and fire hydrants:
Preparation of the surface : SA 2.5 sanding or hammering
Internal coating : Pure epoxy, average thickness 150 micron
External coating (for the parts outside) : Epoxy, average thickness 100 micron
External coating (for built-in parts) : Epoxy, average thickness 200 micron
5.10.1 Dismountable Joints
Dismountable or adjustable/dismountable joints shall be supplied that have been

manufactured in such way that all valves, of which the diameter exceed 100 mm, all pumps in
the pumping facilities and the complex piping systems in the pumping stations can be
dismounted.
5.10.2 Surface Boxes
The surface boxes shall be manufactured in accordance with ISO 3531 or BS 5834
from cast iron and coated with a tar-based material.
5.10.3 Flanged Anchoring Sleeves
Flanged anchoring sleeves complying with ISO 2531 shall be used at all locations
where the iron pipes pass through a concrete wall or structure.
5.11 Pipe Support
The Contractor shall ensure that sufficient pipe support is achieved during the process
of laying the pipes until the permanent support and anchorage works or the other measures
that have been approved by the Control Engineer have been completed. The Contractor shall
174
see to it that excessive tensions and loads is not imposed on the fittings, pipes or structures
during the process of laying the pipes. The piping system shall be completed and it shall be
checked before or after the pipes are buried in the concrete whether or not the pipes are at the
right position and correctly aligned.
5.12 Marking Posts of Route
Marking posts shall be supplied and erected by the Contractor in order to permanently
mark the route and depth of the underground lines and pipelines, which will comply with the
typical details shown on the drawings and on which a plate with the necessary information
will be installed. There is no need to erect marking posts along the sewage lines that are
equipped with manholes.
The marking posts shall be erected in the shortest possible period after the trench
excavations have been filled. However, the Contractor shall also supply the provisional
marking posts and shall be responsible for the correct information on the plates.
The marking posts shall be erected with a distance of 200 m between them at the
locations where the line changes the direction, beside all valves, valve chambers, closed pipe
ends and at the other locations that could be requested by the Control Engineer. The depth of
the upper point of the pipeline shall be indicated on all marking plates. The distance between
the marking posts could be changed in line with the request brought forward by the Control
Engineer in order to prevent the obstruction of the traffic or other land utilizations.
5.13 Corrosion Protection
Polyethylene coating shall be established in accordance with the drawings and at the
locations required by the Control Engineer. The coatings shall be applied in accordance with
the instructions of the manufacturer. The separate protection of the protective windings and
joints and uninterrupted winding along the joints shall be included in the implementation
method.
5.14 Testing of Pipeline
The pressurized pipelines (together with all accessories, house valves) shall be tested
with water according to BS 6700. The trenches shall be filled up to half of the pipe, the joints
shall be in the open and as a result while the movement of the pipeline is prevented, access to
the joints shall be possible. The determination masses should have been constructed prior to
the test. The backfilling of the joints can be carried out on condition that written permit is
obtained from the Employer on the roads with heavy traffic.
The Employer shall be notified of the issue in written form at least two days before a
pressure test has been carried out at any part of the pipeline.
The test pressures at the water and sewage pipes shall be at the level as required in the
project.
175
The pipes shall be filled in appropriate lengths that will not exceed 500 m and tested.
The length that will be subject to test at one time regarding the pipes laid with inclination
shall be specified according to the instructions of the Employer.
The ends of the pipes that will be tested shall be closed with plugs or with blind
flanges with anchorage that will be supplied by the Contractor. The valves shall not be used
for this purpose. Blind flanges shall be installed in place of all cleaning and air discharge
valves before the start of the test.
The pipes shall be filled slowly and carefully with water in such way to prevent a
water impact after the pipes have been laid, joined and anchored and the air in the pipeline
shall be let outside from the upper point of the air pipe or by constructing a service connection
with cock if there is a higher point in between. The pipes, of which the internal surface have
been covered with mortar, shall be left to wait at least for 24 hours as filled with water before
the test.
The test pressure shall be applied by using a test pump that will be controlled
manually or with an engine and that will be connected to two parallel manometers that have
been calibrated in an approved laboratory. The test pressure that will not be reduced by more
than 0.2 bar shall be applied at least for a period of 30 minutes.
It shall be tested during the course of the test if there is a leakage in the pipe joints but
the test period shall not exceed 2 hours. A reduction of 0.3 bar in the pressure shall be
permitted if this period is exceed.
In the case that leakage is observed in the joints, the joint shall be dismounted and
mounted again in order to eliminate the leakage or if this is not possible the Contractor shall
supply new joints and install them. In case of the occurrence of a hole or any leakage in a pipe
or joint, the Contractor shall replace the flawed of the pipe or joint. In such cases, the length
of the pipeline that had been tested shall be subject to a new test as described above and these
operations shall be repeated until it can be satisfactorily substantiated that the pipeline can
withstand the test pressure.
A pipe report shall be prepared for each test that will be carried out. At least the
following information shall be included in this report:
 Number and date of the test,

 The length tested and a clear description of the end points of this length,
 A list exhibiting the sequence of pipe laying in the pipeline section that has been subject
to the test, the number and characteristics of the pipes, the fittings and other parts that
have been used,
 Test period, test pressure and the results that have been obtained,
 Decisions and results pertaining to the likely repairs.
Test Report shall be signed by the Contractor and Employer.
The Contractor shall provide the necessary workmanship for the test as subject to the
approval of the Employer and supply, install and operate the test pump, manometer and other
equipment and shall first fill the pipes with water and then discharge the water after the test.
The water that will be drained from pipes shall be removed in such way that the stability of
the works carried out or the adjacent buildings shall not be spoiled.
176
All expenditures pertaining to the tests shall be assumed to have been included in the
unit prices or amounts related to the laying of the pipeline submitted by the Contractor.
5.15 Cleaning of Pipeline
The cleaning and disinfection of the pipeline shall be carried out in accordance with AWWA
C 651 in four stages.
Pre-cleaning:
All pipes, of which the diameter is between 100 mm and 600 mm (including 600 mm), shall
be subject to a pre-washing for at least once using fast flowing water (at least 1.5 m/sec). The
Contractor shall draw up a washing plan and submit it to the Control Engineer for approval.
Cleaning:
All pipes shall be cleaned for a period of at least 5 minutes using clean water with a flow
amount over 1 m/sec. This operation shall be repeated so long until there is no odor or taste in
the water.
6 LAYING OF PVC, CTP PIPES
6.1 Laying of Pipes
The Contractor shall submit its own detail projects together with the recommendations
of the pipe manufacturer with regard to the transport, placement in the open canals and
jointing of the pipes and fittings to the Control Engineer for approval. The other methods that
will be suggested for the construction of the pipeline shall be explained in detail within the
recommendations of the pipe manufacturer.
The Contractor shall lay the flexible pipes and fittings in accordance with the placing
recommendations of the pipe manufacturer and in the way as approved by the Employer. The
flexible pipes shall be laid in the approved material other than at the places where protection
with cement is necessary and then covered. The granulated material shall cover the entire
width of the canal and shall be laid along the entire pipeline 150 mm under the sockets and
couplings or 150 mm above the upper part of the pipes or in the manner as foreseen by the
Employer. The granulated material shall be compressed manually.
The pipeline and similar materials must be checked before the laying of the pipeline,
the spigots and rubber gaskets must be cleaned using a wet cloth. In the case that some
sections of the pipes are damaged, these sections must be cut off and removed. The PVC
pipes shall be cut with fine-toothed saw. The cut must be perpendicular to the axis and clean.
It would be useful to remove the burrs and other rough parts. The outer edge of the
ends that have been cut shall be coned with a depth that is half of the wall thickness of the
pipe and with an angle of 15o’lik.
The pipelines shall be laid with the inclination indicated in the project. The inserted
spigots shall be placed to face the hill at large inclinations.
177
The sliding material supplied from the pipe factory shall be applied to facilitate the
access of the pipe ends in the spigots. No other art of sliding material shall be used. Special
tools shall be used for pushing the pipes with a diameter over 100 mm in the spigots. The pipe
ends shall not be pushed in the spigot all the way up to the end and a clearance of
approximately 10 mm shall be left for expansion. The recommendations of the authorized
persons of the pipe manufacturer shall be taken into consideration for specifying the actual
value of this clearance.
The pipes shall be laid in the direction that has been foreseen unless there is an
obligation. The tolerance for the deviation from the direction is 1 cm at a length of 4 m and on
the axis of the pipe.
The bends, branch points and the line ends must be fixed as necessary with concrete
supports. Furthermore, the long pipelines laid in the correct direction shall be sufficiently
supported at the trench edges.
The necessary measures must be taken to prevent that damage will be inflicted on the
supports, fixation masses and pipeline because the bottom will be softened as a result of the
precipitation and other waters coming to the trench. The trenches cannot be left open for a
long period of time at dangerous grounds.
All open ends of the pipes that are being laid shall be tightly closed during the work
interruptions in order to prevent the access of foreign substances.
The necessary measures shall be taken to prevent any damage being inflicted on the
pipeline by the impacts resulting from the vehicles. The transfer of effect of the impacts to the
pipeline should be prevented with armatures particularly at the network lines. To this end, the
pipeline must be buried sufficiently in the ground so that the needles of the valves and fire
faucets shall not be subject to direct wheel load. The concrete cushions that should be under
the armatures must also be placed as needed and without flaw.
After the pipeline has been laid, the trench shall be filled and compressed in such way
and with the correct thickness that the connection places is open during the test period and the
movement of the pipes shall be prevented during the test. The filling material from the trench
bottom up to 30 cm from the upper point of the pipe must be free of stones. Hand hammers
shall be used in this section for compressing the ground. The grains larger than 3 cm shall be
considered as stones.
The inserted pipes with spigot, which will be laid in trenches with underground water
in them, shall be lowered in the trench by jointing in parts outside the trench and shall be laid
on the trench bottom by pressing with filling soil. In such cases, the pre-pressure test shall be
carried out with pressurized air of 1 atm.
The laying of PVC pipes at a temperature under zero degree shall not be recommended. In the
cases where work must be carried out, they should be laid vet carefully by making sure that
they will not be subject to any impact.
178
6.2 Pipe Trenches
The trench depth should at no point be less than the frost depth. Special measures
should be taken in cases of necessity against frost damages with the approval of the
Employer.
Leaving an empty stripe of 50 cm width along the length of the trench and at both
sides of the trench between the side of the trench and the soil extracted from the excavation
shall be recommended.
In the case that there are stones in the material extracted during the excavation, the
necessary measures must be taken to prevent that they roll into the trench and damage the
pipeline.
The trench bottom shall be straight out. The pipeline shall be placed on the bottom
along the length. Supports in form of point should be avoided since such support leads to
fractures of the pipe.
The trench shall be excavated 15 cm deeper at the grounds with rocks and stones and
the trench shall be filled with the fine grained material, soil or clay as much as the extra
excavation and the pipe shall be laid on top of it after it has been compressed. In the cases
where the filling is removed or reduced as a result of rain or similar reasons, it should be
restored. The trench bottom shall be fortified at the grounds that are not robust.
In the case that changing layers at the trench bottom and varying bearing strength
depending on that is in question, filling with fine gravel or sand with sufficient thickness shall
be constructed at the crossing places of the layers with the permission obtained from the
Employer.
6.3 Pipe Connections
All connections in the pipeline should be sound and waterproof.
Special passage parts shall be used at the connections to other arts of pipes. The plastic
pipes should not be threaded.
The connections that shall be used most frequently:
a. Gluing,
b. Tayton type,
c. Pimadur type,
d. Reka type.
The following shall be taken into consideration at the manufacture of abutment for
connection:
In the case that abutment is carried out by heating the pipeline and putting a hot
template in it, naturally there shall be an expansion of the diameter, which leads to the
reduction of wall thickness and the wall thickness of the abutment shall be less than the wall
179
thickness of the pipe. The wall thickness of this section should be more than the wall
thickness of the pipe because the diameter has been enlarged. There are methods for providing
excessive wall thickness at the abutment section. If this cannot be achieved, the pipe can only
be operated at the pressure that corresponds to the diameter and wall thickness at the abutment
section. A solution without abutment would be that straight pipes are connected with
clamping sleeves with more wall thickness but it must be taken into consideration that in such
case the connection number will be doubled.
Good quality material must be used for the pipe connections. The gluing material
amounts are given below:
Main diameter of the 50 65 80 100 110 125 150

pipe, mm
Outside diameter of 63 75 90 110 125 140 160
the pipe, mm
Glue, g 12 17 23 34 44 53 69
The types such as Tayton type, Pimador type and the like that allow elongation are the
preferred types.
6.4 Testing of Constructed Pipeline
6.4.1 Length of Pipeline
The length of the pipeline that will be subject to the pressure test should not be more
than 500 m.
6.4.2 Supporting and Fixing of Pipeline

Not only the pipe ends but also all vertical and horizontal bends and forks must be
supported and fixed as needed before filling the pipeline with water. This way, the
movements of the pipeline and the leakage of water from the joints during the operation shall
be prevented.
The supports and fixation kits must be calculated according to the test pressure to be
applied. The compression tensions affecting the ground should be taken into consideration
here.
The supports at the end of the line should not be removed before the pressure has been
totally reduced.
Fixing the pipeline at the trench sides in appropriate intervals would be useful at
straight lines too. Taking into consideration that particularly at the pipelines that cannot take
axial force (inserted, with spigot, etc.) the pipes shall deviate from the axis, the top of the
pipes shall be sufficiently filled in such way that the heads will be in open to ensure that they
do not move under pressure.
180
6.4.3 Filling of Pipeline
The pipelines shall be filled with water of appropriate characteristics in such way that
there will be no air in the pipeline.
6.4.4 Manometer Installation
The manometer to be used for the pressure test must be adjusted and accurate.
Furthermore, another manometer must be available as backup. The manometer shall be
generally installed at the lowest point of the line.
6.4.5 Preliminary Test
A preliminary test shall be carried out as a preparation before the test pressure has
been established. The preliminary test shall be carried out with static pressure and at least for
a period of 2 hours.
There should be no water leakages in the pipes, special parts, armatures and all kinds
of connection places so that this test can be considered to be acceptable.
6.4.6 Water Leakage
In the case that water leakage (drops, water leakage, etc.) is set out during the
preliminary test, the test shall be interrupted and the pipeline shall be slowly emptied until
there is no water in the pipeline. The test shall be repeated after the leakages have been
eliminated.
6.4.7 Main Test
The main test shall be immediately started if the preliminary test is successful. The
main pressure test shall be carried out for a period of two hours using a pressure that is 1.3
times the static pressure if the test is to be carried out at the gravity water supply pipeline and
1.3 times the maximum working pressure if the test is to be carried out at the elevation line.
At the end of the test:

a ) If the pressure reduction is at the most 0.25 kg/cm2,
b ) If a movement in the pipeline not detected at the end of the examination of the line as a
result of the insufficiency of the support fixations and anchorages or no signs of movement
that could lead to water leakages at a later time, the test shall be considered to have yielded
positive results.
181
6.4.8 Connection Places of Partial Pipelines
This shall have a length maximum 500 m and it must be detected that there is no water
leakage at the connection places of the pipelines that will be subject to the main pressure test
under the least static pressure (if possible, the main test pressure).
6.4.9 Activation of Pipeline
The pipeline shall be activated after the pressure tests have been carried out in
accordance with the relevant specifications of the Employer and the subsequently the PVC
pipelines laid in accordance with the project have been well washed and disinfected according
to the relevant specification of the Employer.
7 THE LAYING OF PE AND HDP PIPES
7.1 Laying of Pipes
The purpose of this specifications is to have maximum productivity for the trench
excavation and workmanship pertaining to the pipe assembly works and at the same time to
ensure the reliability of the assembly.
The trench shall consist of three layers and shall contain the following materials:
Upper layer: Compressed soil filling (except for road passages),

Jacket layer: Compressed soil filling free of hard substances,
Cushion layer: Compressed sand.
The relationships of the cushion layer height (y) and trench width (b) according to the
pipe diameter (d) are given below:
For D < 600 mm, y = 20 cm , b = D + 2 x 20 cm
For 600 mm < D < 1000 mm, y = 20 cm , b = D + 2 x 30 cm
For D > 1000 mm, y = 30 cm , b = D + 2 x 30 cm
The distance between the upper level of the pipe and the natural ground (H upper) should
be minimum 50 cm.
182
7.2 Calculation Methods
The definitions used in the calculations are given below:
Standard Dimension Rate (SDR) = Nominal outside diameter (, mm) / Wall
thickness (s, mm)
Hydrostatic Design Tension () = MRS / C (Mpa)

Hydrostatic Pressure (nominal pressure) (P, Bar) = 2 s / (D – s)
PE Pipe Wall Thickness (s, mm) = P x D / 2  + P
The roughness coefficient of the HDPE (High Density Polyethylene) pipes used in the
pressurized lines
For Colebroke White 0.02 mm
For Hazen Williams 149
For Darcy Weissbach 0.02 mm dir.
7.3 Effect of Temperature
The response of polyethylene to temperature changes is more clear when compared

with many materials. The linear temperature expansion coefficient for each 1 C shall be
accepted as 1.5 x 10-4 m/m oC.
The expansion and shortening amounts during the temperature changes in the PE pipe
shall be given in mm in the table below:
Table: Temperature Expansion/ Shortening Amounts (mm)

PIPE TEMPERATURE DIFFERENCE (T) o C
LENGTH (m) 10 20 30 40
1 1.5 3 4.5 6
6 9 18 27 36
12 18 36 54 72
50 75 150 225 300
100 150 300 450 600
The temperature is an important factor that also influences the mechanical

characteristics of polyethylene. Polyethylene can protect its mechanical characteristics at
temperatures between – 50 C and + 50 C.
183
7.4 Testing of Constructed Pipeline
7.4.1 Length of Pipeline
The length of the pipeline that will be subject to the pressure test should not be more
than 500 m.
7.4.2 Supporting and Fixing of Pipeline
Not only the pipe ends but all vertical and horizontal bends and forks should be
supported and fixed as needed before filling the pipeline with water. This way the movement
of the pipeline and as a result the water leakage at the joints during the test and operation shall
be prevented.
The supports and fixation masses must be calculated according to the test pressure to
be applied. The compression tension that will be applied to the ground should be taken into
consideration here.
The supports at the end of the line should not be removed before the pressure has been
completely reduced.
Fixing of the pipes at the trench sides at appropriate intervals shall be useful at straight
lines too. Taking into consideration that particularly at the pipelines that cannot take axial
force (inserted, with spigot, etc.) the pipes will deviate from the axis, the top of the pipes will
be sufficiently filled in such way that the heads will be in open to ensure that they will not
move under pressure.
7.4.3 Filling of Pipeline
The pipelines shall be filled in such way with water of suitable characteristics that
there won’t be air in the pipeline.
7.4.4 Manometer Installation
The manometer to be used for the pressure test must be adjustable and accurate.
Furthermore, another manometer must be available as backup. The manometer shall be
usually installed at the lowest point of the line.
7.4.5 Preliminary Test
A preliminary test shall be carried out as a preparation before the test pressure has
been established. The preliminary test shall be carried out with static pressure and at least for
a period of 2 hours.
184
There should be no water leakages in the pipes, special parts, armatures and all kinds
of connection places so that this test can be considered to be acceptable.
7.4.6 Water Leakage
In the case that water leakage (drops, water leakage, etc.) is set out during the
preliminary test, the test shall be interrupted and the pipeline shall be slowly emptied until
there is no water in the pipeline. The test shall be repeated after the leakages have been
eliminated.
7.4.7 Main Test
The main test shall be immediately started if the preliminary test is successful. The
main pressure test shall be carried out for a period of two hours using a pressure that is 1.3
times the static pressure if the test is to be carried out at the gravity water supply pipeline and
1.3 times the maximum working pressure if the test is to be carried out at the elevation line.
At the end of the test:

a ) If the pressure reduction is at the most 0.25 kg/cm2,
b ) If a movement in the pipeline is not detected at the end of the examination of the line as a
result of the insufficiency of the support fixations and anchorages or no signs of movement
that could lead to water leakages at a later time, the test shall be considered to have yielded
positive results.
7.4.8 Connection Places of Partial Pipelines
The length shall be maximum 500 m and it must be specified that there is no leakage
at the connection places of the pipelines that will be subject to the main pressure test under
minimum static pressure (if possible, main test pressure).
7.4.9 Activation of Pipeline
The pipeline shall be activated after the pressure tests have been carried out in
accordance with the relevant specifications of the Employer and the subsequently the PVC
pipelines laid in accordance with the project have been well washed and disinfected according
to the relevant specification of the Employer.
185

Pi̇pe Works

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Pi̇pe Works

Загружено:

Авторское право:

Доступные форматы

CONTENTS

1 SUBJECT AND SCOPE....................................................................................................20

2 STEEL MATERIAL CHARACTERISTICS..................................................................20

2.2 Chemical Composition.....................................................................................................20

2.3 Mechanical Characteristics.............................................................................................20

3.2 Weld Seam........................................................................................................................22

3.3 Dimensions and Dimension Tolerances.........................................................................22

3.5 Pipe Straightness..............................................................................................................25

3.8 Marking of Pipes and Special Parts...............................................................................25

4 ISOLATION OF STEEL PIPES......................................................................................26

4.1 Cleaning of Pipe Surfaces................................................................................................26

4.2 Isolation of Pipe External Surfaces................................................................................26

4.3 Internal Isolation of Steel Pipes......................................................................................28

5 SAMPLING, INSPECTION AND TESTS......................................................................31

5.2 External Coating Inspection and Tests..........................................................................33

5.3 Characteristics of Manufactured Pipe...........................................................................35

5.5 Pipe Delivery and Quality Warranty.............................................................................35

6 GENERAL DELIVERY CONDITIONS FOR PIPES...................................................35

6.2 Place of Delivery:.............................................................................................................35

6.3 Transport and Storage of Pipes......................................................................................35

9.1 Visual inspection..............................................................................................................38

9.2 Dimensional Inspection...................................................................................................38

9.3 Pipe Isolation Test............................................................................................................38

9.4 Production Tests...............................................................................................................38

9.5 Factory Made Bends........................................................................................................39

9.6 Tees and Y’s....................................................................................................................39

9.7 Steel Pipes with Rubber Gasket Spigots........................................................................39

9.8 Coating of Weld Seams....................................................................................................40

13 ACCEPTANCE - CONDITIONAL ACCEPTANCE - REJECTION........................41

13.2 Conditional Acceptance.................................................................................................41

17 TRANSPORT AND STORAGE.....................................................................................42

HDPE 100 (HIGH DENSITY POLYETHYLEN) PIPES..................................................43

1 SUBJECT AND SCOPE....................................................................................................43

2.4 Raw Materials..................................................................................................................44

2.5 Technical Characteristics................................................................................................45

2.6 Pipe Jointing Methods.....................................................................................................46

2.7 Wear Resistance...............................................................................................................46

2.8 Nominal Pressure.............................................................................................................46

2.9 Special Conditions............................................................................................................47

3 INSPECTION AND TESTS..............................................................................................47

4 DIMENSIONS AND TOLERANCES..............................................................................47

8 TRANSPORT AND STORAGE OF PIPES....................................................................48

8.1 Loading and unloading of pipes......................................................................................48

8.2 Storage of pipes................................................................................................................49

10 DIMENSIONS AND QUANTITY OF STEEL PIPES TO BE SUPPLIED...............50

11 GENERAL DELIVERY CONDITIONS FOR PIPES.................................................50

GLASS REINFORCED PLASTIC (GRP) PIPES...............................................................51

2.1 Glazing gasket..................................................................................................................51

2.3 Glass Texture....................................................................................................................51

2.4 Surface Tulle.....................................................................................................................52

2.5 Coating Layer...................................................................................................................52

2.7 Glass Felt...........................................................................................................................52

2.9 Nominal Pressure.............................................................................................................52

2.10 Nominal Rigidness.........................................................................................................52

3.1 Sleeve Joint.......................................................................................................................53

3.2 Gasket Spigot Joint..........................................................................................................53

3.3 Hand lay-up connection...................................................................................................53

3.4 Flanged Joint....................................................................................................................53

4.1 Classification by Pressure Classes..................................................................................53

4.2 Classification by Rigidness Classes................................................................................54

5.1 Fiber Wrapping Method.................................................................................................54

5.2 Centrifugal Casting Method...........................................................................................55