Technical Specifications

HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS

PART 1 GENERAL

1.1 SECTION DESCRIPTION

1.1.1 This specification includes but is not limited to high-density polyethylene (PE
3408) (ductile iron pipe size O.D) pressure pipe primarily intended for the
transportation of water and sewage either buried or above grade.
1.2 REFERENCES
1.2.1 AWWA C901 Polyethylene (PE) pressure Pipe & Tubing, inch through 3 inch
for water
1.2.2 AWWA C906 Polyethylene (PE) pressure Pipe & Fittings, 4 inch through 63 inch
for water
1.2.3 ASTM D3035 Standard Spec for PE Pipe (DR-PR) Based on Controlled Outside
Diameter
1.2.4 ASTM D3261 Butt Heat Fusion PE Fittings for PE Pipe & Tubing
1.2.5 ASTM D3350 Standard Specification for PE Pipe & Fittings Materials
1.2.6 ASTM D1238 Melt Flow Index
1.2.7 ASTM D1505 Density of Plastics
1.2.8 ASTM D2837 Hydrostatic Design Basis
1.2.9 NSF Std.#14 Plastic Piping Components & Related Materials
1.2.10 TR-33/2005 Generic Butt Fusion Joining Procedure for Field Joining of PE Pipe
1.3 GENERAL
1.3.1 USE
1.3.1.1 High Density Polyethylene (HDPE) pipes/fittings shall be allowed for
use as water, wastewater and reclaimed water pressure pipe where
compatible with the specific conditions of the project. The use of
material other than HDPE pipe may be required by ASPA if it is
determined that HDPE pipe is unsuitable for the particular application.
All material used in the production of water main piping shall be
approved by the National Sanitation Foundation (NSF).
1.4 DOCUMENTATION
1.4.1 Documentation from the resins manufacturer showing results of the following
tests for resin identification:
1.4.1.1 Melt Flow Index ASTM D1238

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 1.4.1.2 Density ASTM D1505
1.5 MANUFACTURER
1.5.1 All HDPE pipe and fittings shall be from a single manufacturer, who is fully
experienced, reputable and qualified in the manufacture of the HDPE pipe to be
furnished. The pipe shall be designed, constructed and installed in accordance
with the best practices and methods and shall comply with these Specifications.
Qualified manufacturers shall be: PLEXCO Division of Chevron Chemical
Company, DRISCOPIPE as manufactured by Phillips Products Co., Inc.,
SCLAIRPIPE as manufactured by DuPont of Canada or equal as approved by the
Utilities Engineer.
1.6 FINISHED PRODUCT EVALUATION
1.6.1 Production staff shall check each length of pipe produced for the items listed
below. The results of all measurements shall be recorded on production sheets,
which become part of the manufacturers permanent records.
1.6.1.1 Pipe in process shall be checked visually, inside and out for cosmetic
defects (grooves, pits, hollows, etc.)
1.6.1.2 Pipe outside diameter shall be measured using a suitable periphery
tape to ensure conformance with ASTM F714 or ASTM D3035,
whichever is applicable.
1.6.1.3 Pipe wall thickness shall be measured at 12 equally spaced locations
around the circumference at both ends of the pipe to ensure
conformance with ASTM F714 or ASTM D3035, whichever is
applicable.
1.6.1.4 Pipe length shall be measured.
1.6.1.5 Pipe marking shall be examined and checked for accuracy.
1.6.1.6 Pipe ends shall be checked to ensure they are cut square and clean.
1.6.1.7 Subject inside surface to a reverse bend test to ensure the pipe is free
of oxidation (brittleness).
1.7 STRESS REGRESSION TESTING
1.7.1 The polyethylene pipe manufacturer shall provide certification that stress
regression testing has been performed on the specific polyethylene resin being
utilized in the manufacture of this product. This stress regression testing shall
have been done in accordance with ASTM D2837 and the manufacturer shall
provide a product supplying a minimum Hydrostatic Design Basis (HDB) of
1,600 psi as determined in accordance with ASTM D2837.
1.8 COMPATIBILITY
1.8.1 Contractor is responsible for compatibility between pipe materials, fittings and
appurtenances.
1.9 WARRANTY

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 1.9.1 The pipe MANUFACTURER shall provide a warranty against manufacturing
defects of material and workmanship for a period of ten years after the final
acceptance of the project by the OWNER. The MANUFACTURER shall replace
at no expense to the OWNER any defective pipe/fitting material including labor
within the warranty period.

PART 2 PRODUCTS

2.1 MATERIALS FOR PIPE SIZES 4-INCH DIAMETER AND LARGER

2.1.1 Materials used for the manufacture of polyethylene pipe and fittings shall be made
from a PE 3408 high density polyethylene resin compound meeting cell
classification 345434C per ASTM D3350; and meeting Type lll, Class C,
Category 5, Grade P34 per ASTM D1238.
2.1.2 High Density Polyethylene (HDPE) pipe shall comply with AWWA
Specifications C906.
2.1.3 If rework compounds are required, only those generated in the Manufacturers
own plant from resin compounds of the same class and type from the same raw
material supplier shall be used.
2.1.4 Dimensions and workmanship shall be as specified by ASTM F714. HDPE
fittings and transitions shall meet ASTM D3261. HDPE pipe shall have a
minimum density of 0.955 grams per cubic centimeter. All HDPE pipe and
fittings shall have a Hydrostatic Design Basis (HDB) of 1,600 psi.
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2.1.5 HDPE pipe and accessories 4-inch diameter and larger, shall be 160 psi at 73.4 F
meeting the requirements of Standard Dimension Ration (SDR) 17 as MINIMUM
STRENGTH.
2.1.6 The pipe Manufacturer must certify compliance with the above requirements.
2.2 MATERIALS FOR PIPE SIZES 2-INCH DIAMETER AND LESS
2.2.1 Materials used for the manufacture of polyethylene pipe and fittings shall be made
from a PE 3408 high density polyethylene resin compound meeting cell
classification 345434C per ASTM D3350; and meeting Type lll, Class C,
Category 5, Grade P34 per ASTM D1238.
2.2.2 High Density Polyethylene (HDPE) pipes shall comply with AWWA
Specifications C901.
2.2.3 If rework compounds are required, only those generated in the Manufacturers
own plant from resin compounds of the same class and type from the same raw
material supplier shall be used.
2.2.4 Dimensions and workmanship shall be as specified by ASTM D3035. HDPE
fittings and transitions shall meet ASTM D3261. HDPE pipe shall have a
minimum density of 0.955 grams per cubic centimeter. All HDPE pipe and
fittings shall have a Hydrostatic Design Basis (HDB) of 1,600 psi.

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 o
2.2.5 HDPE pipe and accessories 2 and less in diameter, shall be 160 psi at 73.4 F
meeting the requirements of Standard Dimension Ration (SDR) 9 as MINIMUM
STRENGTH.
2.2.6 The pipe Manufacturer must certify compliance with the above requirements.
2.3 FITTINGS
2.3.1 All molded fittings and fabricated fittings shall be fully pressure rated to match
the pipe SDR pressure rating to which they are made. All fittings shall be molded
or fabricated by the manufacturer. No Contractor fabricated fittings shall be used
unless approved by the Engineer.
2.3.2 The manufacturer of the HDPE pipe shall supply all HDPE fittings and
accessories as well as any adapters and/or specials required to perform the work
as shown on the Drawings and specified herein.
2.3.3 All fittings shall be installed using butt-fused fittings, thermo-fused
fittings/couplings, or flanged adapters and must be approved by the Engineer. NO
size on size wet taps shall be permitted.
2.3.4 All transition from HDPE pipe to ductile iron or PVC shall be made per the
approval of ASPA Engineer and per the HDPE pipe manufacturers
recommendations and specifications. A molded flange connector adapter within a
carbon steel back-up ring assembly shall be used for pipe type transitions. Ductile
iron back-up rings shall mate with cast iron flanges per ANSI B16.1. A 316
stainless steel back-up ring shall mate with a 316 stainless steel flange per ANSI
B16.1.
2.3.4.1 Transition from HDPE to ductile iron fittings and valves shall be
approved by ASPA Engineer before installation.
2.3.4.2 No solid sleeves shall be allowed between such material transitions.
2.3.4.3 Fittings and transitions shall be as manufactured by Phillips
DRISCOPIPE, Inc., 1000 Series Pressure Pipe, Chevron Chemical
Company Plexco/Spiralite pipe, or equal.
2.3.4.4 The pipe supplier must certify compliance with the above
requirements.
2.4 PIPE IDENTIFICATION
2.4.1 The following shall be continuously indent printed on the pipe or spaced at
intervals not exceeding 5-feet:
2.4.1.1 Name and/or trademark of the pipe manufacturer.
2.4.1.2 Nominal pipe size.
2.4.1.3 Dimension ratio.
2.4.1.4 The letters PE followed by the polyethylene grade in accordance with
ASTM

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 2.4.1.5 D1248 followed by the hydrostatic design basis in 160s of psi, e.g.,
PE 3408.
2.4.1.6 Manufacturing standard reference, e.g., ASTM F714 or D-3035, as
required.
2.4.1.7 A production code from which the date and place of manufacture can
be determined.
2.4.1.8 Color Identification, either stripped by co-extruding longitudinal
identifiable color markings or shall be solid in color and as follows:
i. BLUE Potable Water
i. GREEN Sanitary Sewer
2.4.2 Tracing Wire
2.4.2.1 Open trench installation of HDPE shall be identifiable per ASPA
Specification Sec. 02600, Part 2, 2.01 (A).
2.4.2.2 Directional Drilled HDPE shall have wire conforming to Copperhead
Industries Reinforced #1245 Extra-High Strength Tracer Wire and
affixed to the drilling head/reamer per Detail M-17.
2.4.3 Marking Tape: Marking tape shall be installed per ASPA Engineer approval.

PART 3 EXECUTION

3.1 JOINING METHOD

3.1.1 The pipe shall be joined with butt, heat fusion joints as outlined in ASTM D2657
and conform to the Generic Butt Fusion Joining Procedure for Field Joining of
Polyethylene Pipe, Technical Report TR-33/2005, published by the Plastic Pipe
Institute (PPI). All joints shall be made in strict compliance with the
manufacturers recommendations. A factory qualified joining technician as
designated by pipe manufacturer or experienced, trained technician shall perform
all heat fusion joints in the presence of the ASPA inspector.
3.1.2 Lengths of pipe shall be assembled into suitable installation lengths by the butt-
fusion process. All pipes so joined shall be made from the same class and type of
raw material made by the same raw material supplier. Pipe shall be furnished in
standard laying lengths not to exceed 50 feet and no shorter than 20 feet.
3.1.3 On days butt fusions are to be made, the first fusion shall be a trial fusion in the
presence of an ASPA Inspector. The following shall apply:
3.1.3.1 Heating plate surfaces shall be inspected for cuts and scrapes and shall
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be free of dirt and residue. Heater surfaces should be between 400 F
O
(minimum) to 450 F (maximum). Measure the temperature @ 12:00,
3:00, 6:00 and 9:00 oclock positions using a pyrometer of infrared
thermometer at locations where the heating plate will contact the
pipe/fitting ends. The maximum temperature difference between any
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two points on a single heating surface must not exceed 24 F. If this

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 temperature is exceeded, the heating plate shall be cleaned per the
manufacturers recommendations.
3.1.3.2 The fusion or test section shall be cut out after cooling completely for
inspection.
3.1.3.3 The test section shall be 12 or 30 times (minimum) the wall thickness
in length and 1 or 1.5 times the wall thickness in width (minimum).
3.1.3.4 The joint shall be visually inspected as to continuity of beads from
the melted material, and for assurance of cold joint prevention (i.e.
joint shall have visible molded material between walls of pipe). Joint
spacing between the walls of the two ends shall be a minimum of
1/16 to a maximum 3/16.
3.1.4 The polyethylene flange adapters at pipe material transitions shall be backed up
by stainless steel flanges conforming to ANSI B16.1 and shaped as necessary to
suit the outside dimensions of the pipe. The flange adapter assemblies shall be
connected with corrosion resisting bolts and nuts of Type 316 Stainless Steel as
specified in ASTM A726 and ASTM A307. All bolts shall be tightened to the
manufacturers specified torques. Bolts shall be tightened alternatively and
evenly. After installation, apply a bitumastic coating to bolts and nuts.

PART 4 INSTALLATION

4.1 High Density Polyethylene (HDPE) Pipe shall be installed in accordance with the
instruction of the manufacturer, as shown on the Drawings and as specified herein. A
factory qualified joining technician as designated by the pipe manufacturer shall perform
all heat fusion joints.
4.2 HDPE shall be installed either by Open Trench Construction or Directional Bore Method.
4.3 Care shall be taken in loading, transporting and unloading to prevent damage to the pipe.
Pipe or fitting shall not be dropped. All pipe or fitting shall be examined before
installation, and no piece shall be installed which is found to be defective. Any damage to
the pipe shall be repaired as directed by the Engineer. If any defective pipe is discovered
after it has been installed, it shall be removed and replaced with a sound pipe in a
satisfactory manner by the contractor, at his own expense.
4.4 Under no circumstances shall the pipe or accessories be dropped into the trench or forced
through a directional bore upon pull-back.
4.5 Care shall be taken during transportation of the pipe such that it will not be cut, kinked or
otherwise damaged.
4.6 Ropes, fabric or rubber protected slings and straps shall be used when handling pipes.
Chains, cables or hooks inserted into the pipe ends shall not be used. Two slings spread
apart shall be used for lifting each length of pipe.
4.7 Pipes shall be stored on level ground, preferably turf or sand, free of sharp objects, which
could damage the pipe. Stacking of the polyethylene pipe shall be limited to a height that
will not cause excessive deformation of the bottom layers of pipes under anticipated

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 temperature conditions. Where necessary due to ground conditions, the pipe shall be
stored on wooden sleepers, spaced suitably and of such width as not to allow deformation
of the pipe at the point of contact with the sleeper or between supports.
4.8 Pipe shall be stored on clean level ground to prevent undue scratching or gouging. The
handling of the pipe shall be in such a manner that the pipe is not damaged by dragging it
over sharp and cutting objects. The maximum allowable depth of cuts, scratches or
gouges on the exterior of the pipe is 5 percent of wall thickness. The interior pipe surface
shall be free of cuts, gouges or scratches.
4.9 Pipe shall be laid to lines and grade shown on the Drawings with bedding and backfill as
shown on the Drawings.
4.10 When laying is not in progress, including lunchtime, the open ends of the pipe shall be
closed by fabricated plugs, or by other approved means.
4.11 Sections of pipe with cuts, scratches or gouges exceeding 5 percent of the pipe wall
thickness shall be removed completely and the ends of the pipeline rejoined.
4.12 The pipe shall be joined by the method of thermal butt fusion. All joints shall be made in
strict compliance with the manufacturers recommendations.
4.13 Mechanical connections of the polyethylene pipe to auxiliary equipment such as valves,
pumps and tanks shall be through flanged connections which shall consists of the
following:
4.13.1 A polyethylene flange shall be thermally butt-fused to the stub end of the pipe.
4.13.2 A 316 stainless steel back up ring shall mate with a 316 stainless steel flange.
4.13.3 A 316 stainless steel bolts and nuts shall be used.
4.14 Flange connections shall be provided with a full-face neoprene gasket.
4.15 All HDPE pipe must be at the temperature of the surrounding soil at the time of
backfilling and compaction.
4.16 If a defective pipe is discovered after it has been installed, it shall be removed and
replaced with a sound pipe in a satisfactory manner at no additional cost to the Owner.
All pipe and fittings shall be thoroughly cleaned before installation, shall be kept clean
until they are used in the work and when laid, shall conform to the lines and grades
required. kinked or otherwise damaged.
4.17 Open Trench Installation:
4.17.1 ASPA Standards and Specification, Section 02200 Utility Excavation,
Trenching, and Backfilling shall apply in its entirety.
4.17.2 The centerline of the pipe shall not deviate from a straight line drawn between the
centers of the openings at the ends of the pipe by more than 1/16-in per foot of
length. If a piece of pipe fails to meet this requirement check for straightness, it
shall be rejected and removed from the site. Laying instructions of the
manufacturer shall be explicitly followed.
4.17.3 Good alignment shall be preserved during installation. Deflection of the pipe shall
occur only at those places on design drawings and as approved by the Engineer.

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 Fittings, in addition to those shown on the Drawings, shall be used only if
necessary or required by the Engineer.
4.17.4 Each length of the pipe shall have the assembly mark aligned with the pipe
previously laid and held securely until enough backfill has been placed to hold the
pipe in place. Joints shall not be pulled or cramped.
4.17.5 Precautions shall be taken to prevent flotation of the pipe in the trench.
4.17.6 When moveable trench bracing such as trench boxes, moveable sheeting, shoring
or plates are used to support the sides of the trench, care shall be taken in placing
and moving the boxes or supporting bracing to prevent movement of the pipe, or
disturbance of the pipe bedding and the backfill. Trench boxes, moveable
sheeting, shoring or plates shall not be allowed to extend below top of the pipe.
As trench boxes, moveable sheeting, shoring or plates are moved, pipe bedding
shall be placed to fill any voids created and the backfill shall be recompacted to
provide uniform side support for the pipe.
4.17.7 Restrained joints shall be installed where shown on the Drawings or as directed
by the Engineer.
4.18 Directional Bore Installation:
4.18.1 Refer to ASPA Specification 02320 - Horizontal Directional Drilling in its
entirety

PART 5 CLEANING

5.1 At the conclusion of the work, thoroughly clean all of the new pipe lines to remove all
dirt, stones, pieces of wood or other material which may have entered during the
construction period by forcing a cleaning swab through all mains 4 or greater. Flushing
velocities shall be a minimum of 2.5 feet per second. All flushing shall be coordinated
with ASPA Inspector and Water Resources Department. Debris cleaned from the lines shall
be removed from the job site.

PART 6 TESTING

6.1 Pressure testing shall be conducted per Manufacturers recommendations and as

approved by the ASPA Engineer.
6.2 All HDPE water mains shall be disinfected prior to pressure testing as per ASPA
specification.
6.3 All HDPE mains shall be field-tested. Contractor shall supply all labor, equipment,
material, gages, pumps, meters and incidentals required for testing. Each main shall be
pressure tested upon completion of the pipe laying and backfilling operations, including
placement of any required temporary roadway surfacing.
6.4 All mains shall be tested at 150 percent of the operating design pressure of the pipe
unless otherwise approved by the Engineer.
6.5 Pressure testing procedure shall be per Manufacturers recommendations or as follows:

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 6.5.1 Fill line slowly with water. Maintain flow velocity less than 2 feet per second.
6.5.2 Expel air completely from the line during filling and again before applying test
pressure. Air shall be expelled by means of taps at points of highest elevation.
6.5.3 Apply initial test pressure and allow to stand without makeup pressure for two to
three hours, to allow for diametric expansion or pipe stretching to stabilize.
6.5.4 After this equilibrium period, apply the specified test pressure and turn the pump
off. The final test pressure shall be held for one to three hours.
6.5.5 Upon completion of the test, the pressure shall be bled off from a location other
than the point where the pressure is monitored. The pressure drop shall be
witnessed by the resident project representative and ASPA representative at the
point where the pressure is being monitored and shall show on the recorded
pressure read-out submitted to the Engineer of Record.
6.6 Allowable amount of makeup water for expansion during the pressure test shall conform
to Chart 6, Allowance for Expansion Under Test Pressure, Technical Report TR 31/9-79,
published by the Plastic Pipe Institute (PPI). If there are no visual leaks or significant
pressure drops during the final test period, the installed pipe passes the test.
6.7 If any test of pipe laid disclosed leakage significant pressure drop greater than the
manufacturers recommended loss, the Contractor shall, at his/her own expense, locate
and repair the cause of leakage and retest the line. The amount of leakage, which will be
permitted, shall be in accordance with AWWA C600 Standards.
6.8 All visible leaks are to be repaired regardless of the amount of leakage.
6.9 The Contractor must submit his plan for testing to the Engineer for review at least 10
days before starting the test and shall notify ASPA Inspector a minimum of 48 hours
prior to test.

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