Table of Contents 1. 2. 3.

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SCOPE ...... 2 APPLICABLE STANDARDS AND CODES........................................................... TECHNICAL REQUIREMENTS.......................................................................... 3.1 Material................................................................................................... 3.2 Pipe Dimensions ...................................................................................... 3.3 Pipe Appearance ...................................................................................... 3.4 Fittings.................................................................................................... 3.5 Fittings Appearance.................................................................................. 3.6 Fittings Dimension ................................................................................... 3.7 Wall Thickness of Fittings ......................................................................... INSPECTION AND TESTING............................................................................ 4.1 Certification and Documentation................................................................ 4.2 Test Results and Frequencies .................................................................... 4.3 Inspection and Audit Requirements ........................................................... 4.4 Acceptance Criteria .................................................................................. 4.5 Defects ................................................................................................... QUALITY ASSURANCE/QUALITY CONTROL ................................................... PACKING, MARKING AND VENDOR DOCUMENTATION.................................. 6.1 Pipe Identification .................................................................................... 6.2 Shipping.................................................................................................. 6.3 Trucking.................................................................................................. 6.4 Silo's....................................................................................................... 2 3

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1.

SCOPE This Material Specification details the minimum requirements for the design, manufacture, testing, inspection and supply of High Density Polyethylene (HDPE) or High Performance Polyethylene (HPPE) pipe material and fittings to be used for transport and collection of sewer water. This specification is intended to be used for PN10 and pipe series SDR 17 applicable for all new projects except for areas were due to different elevation level/ different project parameters other requirement apply e.g. SDR11 with PN 16. Contractor has to substantiate the reason when he is deviating from SDR 17 and has to get approval from CLEARFORD.

2.

APPLICABLE STANDARDS AND CODES The following codes and standards, to the extent specified herein, form a part of this specification. The latest edition of these codes and standards shall govern the work. ISO 4427 ISO 161-1 ISO 1167-1to4 ISO 3126 ISO 4065 ISO 6964 Polyethylene (PE) pipes for water supply specifications Thermoplastic pipes for conveyance of fluids nominal outside diameter and nominal pressure- part 1: Metric series Thermoplastic pipes, fittings and assemblies for the conveyance of fluids Plastic pipes Measurement of dimensions Thermoplastic pipes Universal wall thickness table Polyolefin pipes and fittings Determination of carbon black content by calcination and pyrolysis Test method and basic specification. Thermoplastic pipes for the transport of fluids Method of extrapolation of hydrostatic stress rupture data to determine the long-term hydrostatic strength of thermoplastic pipe materials. Thermoplastic pipes for the conveyance of fluids Dimensions and tolerances Part: 1: Metric series. Thermoplastic materials for pipes and fittings for pressure applications Classification and designation overall service (design) coefficient. Plastic pipes and fittings pressure reduction factors for polyethylene pipeline systems for use at temperatures above 20 C. Metallic flanges Part 3, Copper alloy and composite flanges Determination of the brittleness temperature by impact
0

ISO 9080

ISO 11922-1 ISO 12162

ISO 13761

ISO 7005 3 ISO 974

ISO 2505 ISO 6259 ISO 1133 ISO 877

Thermoplastics pipes - Longitudinal reversion Determination of tensile properties Determination of the melt mass-flow rate (MFR) and the melt volume-flow Methods of exposure to direct weathering

3. 3.1 3.1.1

TECHNICAL REQUIREMENTS Material Material Requirements The CONTRACTOR shall identify the manufacturer of the resin, the resin type and classification. In addition, the CONTRACTOR shall provide evidence that the resin proposed is suitable for use at the design temperature and under the design pressures indicated. Any change in the material, the material specification, or the manufacturer's location shall be subject to prior approval of CLEARFORD. Pipes and fittings shall be homogenous throughout and free from visible cracks, holes, foreign inclusions, blisters, dents or other damaging defects. Material shall be uniform in opacity, density, interior smoothness, and other physical properties. It shall have adequate resistance to weathering and other ageing from storage for a minimum of two years after manufacture. For the manufacturing of pipes & fittings new materials to be used only (Rework material is not acceptable). Pipe manufacturer shall confirm that all fittings to be provided for the pipe systems shall meet the same quality requirements as for the pipes to ensure the same performance for design life cycle. The pipes and fittings shall be manufactured from polyethylene containing only those antioxidants, UV stabilisers and pigments necessary for the manufacturing process to fulfil the requirements of the specification. All pipes and fittings shall be suitable for butt fusion or electro fusion techniques. Contractor shall provide PE manufacturers guideline for the applicability of the material used. If required PE manufacturers shall provide assistance and training.

3.1.2

Physical Properties Pipes and fittings shall be made of high density polyethylene (HDPE) and shall comply with the requirements of ISO 4427 PE 100. The material used for the manufacturer of pipes and fittings shall be in accordance with Table 1 and Table 2 of clause 4.4 of ISO 4427-1

The minimum required strength (MRS) of the material compound shall be 10 MPa at 20 C. The design stress shall be 8 MPa. Lifecycle durability of 80 years is to be confirmed. The design temperature shall be 36 C For design calculation, pressure, reducing coefficients 4427-1, Annex A are applicable. The thermal stability of polyethylene material shall meet the requirements of ISO 4427. 3.2 Pipe Dimensions (Geometrical Characteristics) The pipe dimensions for water systems shall be based on standard dimensions according to ISO 4427 and measured in accordance with ISO 3126. Straight pipe shall be supplied in standard lengths measured at 23 C + 2 C. Unless otherwise specified, coil lengths shall not exceed 100 m. Coiled pipes shall be coiled such that localized deformation is voided and the minimum internal diameter of the coil shall not be less than 18 d n. 3.3 Pipe Appearance When viewed without magnification the internal and external surfaces of pipes shall be smooth, clean and free from scoring, cavities and other surface defects. The pipe ends shall be cut cleanly and square to the axis of the pipe. The carbon black content in the compound shall be 2.25 + 0.25 % by mass when measured in accordance with ISO 6964. The dispersion of carbon black when determined in accordance with ISO 11420 shall be equal to or less than grade 3. 3.4 Fittings The fittings shall be injection moulded or formed from material compatible to that of the pipe and shall be as resistant to the external and internal environments as the other demands' of the pipe system. At locations where HDPE to metal connections are specified, Nylon based polyamide 11 coating system complying with the requirement of AWWC224 or epoxy coated backing rings shall be used, or special restrained transition fittings subject to approval by CLEARFORD,. The flanges shall be drilled to ISO 7005-2, as per the design requirements. 3.5 Fittings Appearance When viewed without magnification the internal and external surfaces of pipes shall be smooth, clean and free from scoring, cavities and other surface defects. The fitting shall be black. 3.6 Fittings Dimensions The dimensions shall be measured in accordance with ISO 3126 3.7 Wall thickness of Fittings The wall thickness of the body of the fitting at any point shall be equal to or greater than the minimum wall thickness of the corresponding pipe.

4.

INSPECTION AND TESTING

4.1

Certification and Documentation CONTRACTOR shall supply CLEARFORD with copies of certificate and test documents. Such documentation shall be subject to CLEARFORD approval prior to shipping.

4.2

Test Results and Frequencies The MANUFACTURER shall establish and maintain a current record of test results according to the requirements of the applicable standards and this specification. The MANUFACTURER shall perform all the tests required by ISO 4427 to demonstrate the characteristics and quality of the resin material and the dimensional tolerances of the pipe. The MANUFACTURER shall document all the tests, with frequencies and results as indicated in ISO 4427. The records shall be kept for 10 years as a minimum.

4.3

Inspection and Audit Requirements Pipe shall comply fully with ISO 4427 and all the additional requirements of this specification. To verify compliance with this specification, CLEARFORD shall reserve the right to appoint an independent third party inspector to witness the applicable qualification tests, review production records, and inspect general handling and shipping procedures.

4.4

Acceptance Criteria The order shall meet the following criteria: A copy of the raw material MANUFACTURER's "Certificate of Quality Control Testing" covering each batch of raw material used for pipes purchased under this specification, shall be available for inspection by the CLEARFORD on request. Pipe wall thickness shall be controlled by continuous scanning using ultra-sound or other qualified devices. These devices shall be regularly calibrated for accuracy by certificated agency. Successful test performance and acceptable results for the testing program outlined in this specification. An acceptable inspection report from an independent third party inspection company according the manufacturer's country. When performed, acceptable results from an independent test audit of any portion of the tests noted in ISO 4427 and this specification.

4.5

Defects When the rejected item is a length or coil of pipe, the lengths or coils manufactured immediately before and after the defective lengths or coils shall be carefully examined. If further defects are found, this is sufficient cause for rejecting the entire batch. This will not apply to local damage that did not occur during manufacture, such as gouges or cuts during handling or transit.

5.

QUALITY ASSURANCE/QUALITY CONTROL A copy of the MANUFACTURER's QA/QC plan shall be submitted to CLEARFORD with its quotation for review and concurrence prior to award. If MANUFACTURER's facility is ISO certified, QA audit requirements shall be waived in favour of ISO 9000 registrar audits.

6.

PACKING, MARKING AND VENDOR DOCUMENTATION

6.1

Pipe Identification and packing The marking information and sequence shall comply with ISO 4427 (clause 11 marking). All pipes and fittings, including test samples shall be clearly and permanently marked using indent printing in a colour that contrasts with the pipe. All pipes shall be indelibly marked at maximum intervals of 1m The marking shall indicate at least the following information:

the manufacturer's name and/or trademark the dimensions (nominal outside diameter x nominal wall thickness) Material and designation the nominal pressure (PN) in bar the pipe series (S or SDR) the production period (date or code) the number of the International Standard.

The maximum quantity of pipe to have the same coil/length number is one silo (coiled pipe) or one bundle (straight lengths). The maximum combined length of pipe in the silo or bundle with the same coil/length number shall not exceed the maximum allowable coil length specified in clause 3.2 of these specifications. When pipe material is boxed, the coil number shall be clearly marked on the outside edge of the box or silo. Invoices and packing lists shall include the date of manufacture and coil/length numbers for all material in the shipment. The fittings shall be packaged in bulk or individually protected were necessary in order to prevent deterioration and contamination. The package shall have at least one label with manufacturer name, type and dimension of the fittings and number of units.

6.2

Shipping The CONTRACTOR/SUPPLIER shall provide packing and shipping procedures for approval by the CLEARFORD and shall comply with the following requirements.

6.2.1

Delivery Delivery of the plastic pipes and fittings to the site, shall be no later than six months after the stamped manufacture date.

6.2.2

Weathering A certificate from the pipe/fitting manufacturers shall be provided, confirming that the products may be stored in the open for minimum of 2 years without any adverse effect.

6.2.3

Tie-Downs Tie-downs shall be at least 100 mm wide and be clean and free from sand, gravel and other such materials. For straight length pipe (up to 12 m), a minimum of 6 tie-downs are required.

6.2.4

Pallets The pallets shall be suitable for transporting the material from the place of manufacture to the designated receiving location without causing any damage to the pipe. The pallets shall not contain any broken planks or extremities that may damage the coiled pipe or straight lengths. They shall be durable enough to prevent loose pallet nails from gouging the bottom coil/straight length.

6.2.5

Overhang Pipe shall not overhang at either end of the trailer.

6.2.6

Stacking The CONTRACTOR/MANUFACTURER shall not ship small coils stacked inside silos of larger coils. Frames manufactured for the containment of straight lengths of polyethylene pipe during transport and storage shall not contain nails or other fastening devices that may damage the pipe.

6.3

Trucking Where pipes are transported by vehicles, the vehicles should have a flat bed and be free from sharp edges or projections. During transport, polyethylene pipes shall be protected from diesel fumes and be continuously supported to prevent movement between the material and its support.

6.4

Silos Silo packs of coiled pipes shall be squarely stacked and well supported on pallets. Coils shall not overhang the pallets and, shall not be stacked higher than 2.3 m.