PDN Handbook Volume II

Government of Maharashtra
Water Resources Department
VOLUME II
For Office Use Only
Government of Maharashtra
HANDBOOK FOR PIPE DISTRIBUTION
NETWORK FOR IRRIGATION
VOLUME II
(SPECIFICATION FOR
VARIOUS TYPES OF PIPE)
2020
INDEX
Page No.
Sr. Description HDPE PVC GRP PSC PCCP BWSC MS DI SWSR PVC
No. of Item PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE P PIPE -O
PIPE
1 Introduction 1 1 1 1 1 1 1 1 1 1
2 Applicable IS 1 1 1-2 1-2 1 1-2 1-2 1 1-2 1

Codes
3 Raw Materials 2 1-2 2 2-3 2 2-3 2-3 1-2 2 2
4 Manufacturin 3-5 2 2-3 3-4 3 3-4 3-5 2-6 2-3

g of Pipes and 3
Specials
5 Sampling 2-5 4 4-5 4 4-5 6-7 6-7 3-4
criteria for
Selection of 3-6
Pipe for 5-7
Testing
Purpose
6 Pre Delivery 7-13 5-8 4-10 5-7 4-8 5-7 8-11 7-13 4-7 6-
Testing of 11
Pipes
7 Marking on 13 8 11 7 8 7-8 11 13 7 11
Pipes
8 Transportatio 13- 8-9 11 7-8 8-9 8-9 11- 13-14 8 11-
n of Pipes 14 12 12
9 Stacking of 14 9-10 12 8 9 9 12 14-15 9 12

Pipes at Site
10 Valves 15 10-11 12- 9 9-10 9-10 12- 15-16 9-10 12-
13 13 13
11 Post-delivery 16 11 13 9 10 10 13 16 10
testing of 13
pipes
12 Site 16- 11-12 13- 10- 10-12 10-12 13- 16-18 10-12 13-
Preparation 17 14 11 15 15
13 Excavation for 17- 12-13 14- 11- 12-13 12-13 15- 18-19 12-13 15-
Pipe Trenches 18 15 12 16 16
HDP PVC GRP PSC PCCP BWSC MS DI SWSR PVC
Sr. Descriptio E PIPE PIPE PIPE PIPE PIPE PIPE PIPE P PIPE -O
No n of Item PIPE PIP
E
14 Laying of 18- 13 15- 12 13 13 16- 19-20 13-14 16
Pipes 19 17 17
15 Jointing of 20- 14-16 17- 13- 14 13-14 17- 20-22 14 16-
Pipes 22 20 15 18 18
16 Field Testing 22 16-17 20- 16 14-15 14-15 18- 22-24 14- 18-
Of Pipeline 21 19 15 20
System
17 Backfilling of 23 17-18 21 17 15-16 15-16 19- 24-25 15-16 20
Pipe Trenches 20
18 Permanent 23- 18-19 22 17- 16 16 20- 25 16
markings of 24 18 21 21
Pipe
alignment
19 Third Party 24- 19-20 22- 18- 16-18 16-17 21- 26-27 16-17 21-
Inspection 25 23 19 22 22
20 Quality 25- 20-21 24- 19- 18-19 18-19 22- 27-29 17-19 22-
Control and 27 25 20 24
Quality 24
assurance
21 Operation,Ma 27 22 25 21 19-20 19-20 24- 29 19
intenance and 25 24
Handing over
of the System
to WUA
22 Mode Of 27- 22-23 26 21- 20 20 25- 29-30 20 25
Measurement 28 22 26
and Payment
Govt. of Maharashtra
SPECIFICATION FOR HIGH

DENSITY POLYETHYLENE PIPE
(HDPE)
2020
0
SPECIFICATION FOR HIGH DENSITY POLYETHYLENE PIPE (HDPE)
1.0 Introduction
HDPE pipe is a type of flexible plastic pipe used for fluid and gas transfer. HDPE
material is a polyethylene thermoplastic made from petroleum and its high level of
impermeability and strong molecular bond makes it suitable for high pressure
pipelines. The toughness and resistance to chemicals as well as the corrosion resistance
and low weight have contributed to its growing use in situations where cost effective
and durable fluid and gas pipe systems are required. HDPE pipe is made from food
grade polyethylene virgin material as such they are safe for the transfer of potable
water.
The Contractor shall provide on-site training on HDPE pipe laying, jointing,
testing and maintenance etc., to the personnel authorized by Engineer-in-Charge. The
contractor should provide technical Manual on HDPE pipes including precautions to be
taken during operation of the pipeline.
2.0 Applicable IS Codes, ISO Codes

The manufacturing, testing, supplying, laying, jointing and testing at work sites
of HDPE pipes shall comply with all currently applicable statutes, regulations, standards
and Codes. In particular, the following standards, unless otherwise specified herein,
shall be referred. In all cases the latest revision of the Codes shall be referred to. If
requirements of this Specification conflict with the requirements of the
standards/Codes, this Specification shall govern. Others Codes not specifically
mentioned here but pertaining to the use of HDPE Pipes form part of these
Specifications.
IS 4984 High Density Polyethylene Pipes for Water Supply
ISO 4427 HDPE pipes and fittings for water supply.
IS 8360 Specifications for fabricated HDPE fittings for potable water
supplies.(Part I to III)
IS 8008 Injection moulded/ machined HDPE fittings for potable water
supplies.(Part I to IX)
IS 7634 Part-II Laying & Jointing of Polyethylene (PE) Pipes
IS 7328 High density polyethylene materials for moulding and extrusion
IS 2530 Methods of test for polyethylene moulding materials and
compounds.
IS 10141 Positive lists of constituents of polyethylene in contact with food
stuffs, pharmaceuticals and drinking water.
IS 9845 Method of analysis for the determination of specific and/or
overall migration of constituents of plastics material and articles
intended to come in to contact with food stuffs
IS 10146 Polyethylene for its safe use in contact with food stuff,
Pharmaceuticals and drinking water.
1
3.0 Raw Materials
Raw material used to manufacture the HDPE Pipes is High Density Polyethylne
of PE 63, PE 80 and PE 100 grade.
a) The material used for the manufacturer of pipes should not constitute toxicity
hazard, should not support microbial growth, should not give rise to
unpleasant taste or odour, cloudiness or discoloration of water. Pipe
manufacturers shall obtain a certificate to this effect from the manufacturers
of raw material as per the satisfaction of the Engineer-in-Charge.
b) High density Polyethylene (HDPE) used for the manufacture of pipes shall
conform to designation PEEWA-45-T-003 or PEEWA-45-T-006 or PEEWA-50-
T-003 or PEEWA-50-T-006 or PEEWA-57-T-003 or PEEWA-57-T-006 of IS 7328.
HDPE conforming to designation PEEWA-45-T-012 or PEEWA-50-T-012 or
PEEWA-57-T-012 of IS 7328 may also be used with the exception that Melt
Flow Rate (MFR) shall be between 0.20 to 1.10 g/10 min. In addition the
material shall also conform to clause 5.6.2 of IS 7328.
c) The Specified base Density shall be between 940.5 to 958.40 kg/cm3 ( both
inclusive) determined at 270C according to procedure prescribed in IS 7328.
The value of density shall not differ from the nominal/agreed value by more
than 3 kg/m3.
d) The Melt Flow Rate (MFR) of the material shall be between 0.20 and 1.10
gm/10 min. (both inclusive) when tested at 190°C with nominal load of 5kgf
as determined by method prescribed in IS 2530. The MFR of the material shall
also be within ±20 percent of the value declared by the manufacturer.
e) The resin shall be compounded with carbon black. The carbon black content
in the material shall be within 2.5 ± 0.5 % and the dispersion of carbon black
shall be satisfactory when tested as per procedure described in IS 2530.
f) The percentage of anti-oxidant used shall not be more than 0.3 percent by
mass of finished resin. The anti-oxidant used shall be physiologically
harmless and shall be selected from the list given in IS 10141.
g) The addition of not more than 10 % of the manufacturer's own rework

material resulting from the manufacture of pipes is permissible. No other
reworked or recycled material shall be used.
2
4.0 Manufacturing of Pipes and Specials
To make pipe lengths, HDPE material is heated and extruded through a die,
which determines the diameter of the pipeline. The wall thickness of the pipe is
determined by a combination of the size of the die, speed of the screw and the speed
of the haul-off tractor. The General manufacturing process of HDPE Pipe is as given the
below.
Pipe Manufacturing Procedure

• Polyethylene raw material is pulled from a silo, into the hopper dryer, which
removes any moisture from the pellets.
• Then it is pulled by a vacuum pump into blender, where it is heated by a barrel
heater. The PE material becomes molten at around 180 degrees Celsius, allowing
it to be fed through a mould/die, which shapes the molten material into a
circular shape.
• After coming through the die, the newly formed pipe quickly enters the 3-4
cooling tanks, which submerge or spray water at the pipe exterior, each one
reducing the temperature of the pipe by 10-20 degrees.
• Because Polyethylene has a high specific heat capacity, the pipe must be cooled
in stages, to avoid deforming the shape, and by the time it reaches the 'haul-off
tractor', it is hard enough to be gently pulled by the 2-3 belts.
4.1 Workmanship/Appearance
Pipes shall be free from all defect including indentations, delaminating,
bubbles, pinholes, cracks, pits, blisters, foreign inclusions that due to their
nature, degree of extent detrimentally affect the strength and serviceability of
the pipe. The pipe shall be as uniform as commercially practicable in colour
opacity, density and other physical properties as per relevant IS Code or
equivalent International Code. The inside surface of each pipe shall be free of
scouring, cavities, bulges, dents, ridges and other defects that result in a
variation of inside diameter from that obtained on adjacent unaffected portions
of the surface. The pipe ends shall be cut clearly and square to the axis of the
pipe.
4.2 Classification of Pipes:
a) Pipes shall be classified according to the grade of materials as given in
following Table No.1
3
Table No.1: Classification of Pipe material (Reproduced from IS 4984)
Sr. Material grade MRS ( Minimum required Maximum allowable
No. strength) of material in MPa hydrostatic design stress
(N/mm2)., @20 Degree Mpa. (N/mm2)
Celsius, 50 years At 20 At 30
degree degree
Celsius Celsius
1 2 3 4 5
i) PE 63 6.3 5.0 4.0
ii) PE 80 8.0 6.3 5.0
iii) PE 100 10.0 8.0 6.3
b) Pipe shall be classified by pressure rating (PN) corresponding to the

maximum permissible working pressure @ 30 degree Celsius, as per
Table No. 2 : Pressure Ratings (Reproduced from IS 4984)

Pressure rating of pipe Maximum permissible working pressure
MPa (N/mm2)
PN 2.5 0.25
PN 4 0.4
PN 6 0.6
PN 10 1.0
PN 12.5 1.25
PN 16 1.60
c) The nominal diameter of pipes covered in IS 4984 are 16, 20, 25, 32, 40, 50,
63, 75,90, 110, 125, 140, 160, 180, 200, 225, 250, 280, 315, 355, 400, 450,
500, 560, 630, 710, 800, 900 and 1000 mm.
d) Pipes shall be designated according to the grade of material followed by

pressure rating and nominal diameter. For ex. PE 63 PN10 DN200 indicates
a pipe pertaining to material grade 63, pressure rating 1 MPa. & outside
diameter 200 mm.
4.3 Injection Moulded/Machined and Fabricated HDPE Fittings
All HDPE fittings / specials shall be of minimum PN 6 or above Pressure
class. Fabricated HDPE fittings shall be in accordance with IS :8360 (Part I to III).
Injection moulded/ machined fittings shall be as per IS: 8008 (Part I to IX ). All
4
fittings /specials shall be moulded at factory only. No fabrication or moulding
shall be allowed at site, unless specifically permitted by the Engineer-In-Charge.
Fittings shall be welded on to the pipes or other fittings by use of Electro - fusion
process.
When engineering HDPE fittings, the manufacturer can either use an
injection molding or create a fabricated fitting. Generally speaking, injection
molds are used to construct fittings up to 12” in diameter. Any fittings over 12”
in diameter are usually fabricated from sections of pipe or other parts. The
larger fittings are fabricated because their size exceeds injection moulding
equipment capacities. Less common fittings may also be fabricated because
their low demand does not constitute the creation of a mould.
4.3.1 Types of Injection Moulded / Machined HDPE Fittings

Various types of Injection Moulded/ Machined HDPE fittings are as given
below.
a) 900 Bend
b) 900 Tee
c) Reducer
d) Ferrule Reducer
e) Pipe ends
f) Sandwitch Flanges
g) Reducing Tees
h) End Caps
4.3.2 Types of Fabricated HDPE Fittings

Various types of fabricated HDPE fittings are as given below.
a) 900 Bend
b) 900 Tee
5.0 Sampling criteria for Selection of Pipe for Testing Purpose
All pipes of the same size, same pressure rating and same grade and also manufactured
essentially under similar conditions of manufacture, shall constitute a lot. For
ascertaining conformity of the lot to the requirements of this specification, samples
shall be selected as per following.
5.1 Dimensional and Visual Requirements
The number of test samples shall be in accordance with following Table No.3. These
pipes shall be selected at random from the lot and in order to ensure the randomness
of selection, a random number table shall be used. In the absence of a random number
table, the following procedure may be adopted.
Starting from any pipe in the lot, count them as 1,2,3, 4, etc, up to r and so on where
r is the integral part of N/n, N being the number of pipes in the lot and n is the number
5
of pipes in the samples. Every rth pipe so counted shall be drawn so as to constitute
the required sample size.
The number of pipes given for the first sample in col 3 of Table No.3 shall be examined
for dimensional and visual requirements given in following para No. 6.1 & 6.2. A pipe
failing to satisfy any of these requirements shall be considered as defective. The lot
shall be deemed to have satisfied these requirements, if the number of defectives
found in the first sample are less than or equal to the corresponding acceptance
number given in Col 5 of Table No.3. The lot shall be deemed not to have met these
requirements if the number of defectives found in the first sample is greater than or
equal to the corresponding rejection numbers given in col 6 of Table 3. If, however, the
number of defectives found in the first sample lies between the corresponding
acceptance and rejection numbers given in col 5 and 6 of Table 3, the second sample
of the size given in col. 3 of Table 3 shall be taken and examined for these
requirements. The lot shall be considered to have satisfied these requirements, if the
number of defectives found in the cumulative sample is less than or equal to the
corresponding acceptance number given in co1 5 of Table 3; otherwise not.
Table No.3 Scale of Sampling for Visual and Dimensional Requirements

(Reproduced from IS 4984)
5.2 Hydraulic Characteristics, Reversion, Overall Migration, Density, MFR and Carbon
Black Content/Dispersion Tests.
The lot having satisfied dimensional and visual requirements as mentioned in 5.1 above
shall be tested for hydraulic characteristics, reversion, overall migration, density, MFR
and carbon black content /dispersion requirements (as mentioned in following para
no. 6.3 to 6.8). A separate sample size for each of the test shall be taken as stipulated
in following Table 4 and selected at random from the sample already examined for
6
dimensional and visual inspection. All the pipes in each of the sample size shall be
tested for compliance in the requirements for hydraulic characteristics, reversion,
overall migration, density, MFR, and carbon black content /dispersion. The lot shall
be considered to have met the requirements of these tests, if none of samples tested
fails.
Table No.4. Scale of Sampling for Tests for Hydraulic Characteristics,

Reversion, Overall Migration, Density, MFR and Carbon Black Content,
Dispersion (Reproduced from IS 4984)
No. of Pipes Sample Size
Upto 150 3
150 to 1200 5
1201 to 35000 8
For sample testing of injection moulded & fabricated specials, sampling criteria shall
be as mentioned in IS 8360 and IS 8008 respectively.
6.0 Pre Delivery Testing of Pipes

Pipe selected as per sampling criteria mentioned in earlier para 5.0 are subject to
following tests before delivery from factory
1. Dimension: Outside diameter, Wall thickness, Length of pipe
2. Visual appearance
3. Internal pressure creep rupture test,
4. Reversion test,
5. Overall migration test,
6. Density,
7. Melt flow rate (MFR),
8. Carbon black content and dispersion
These test shall be carried out by the contractor in the presence of

representative of Engineer In-charge /WRD/QC/TPI.
6.1 Dimensions:
6.1.1 Outside Diameter:

The outside diameter of pipes, tolerance on the same and ovality of pipe
shall be as given in following Table 5.
7
TableNo.5 Outside diameter, tolerance and ovality of pipes
(reproduced from IS 4984)
Nominal Outside Tolerance (mm) (Only Ovality
Diameter DN Diameter (mm) +ve Tolerance) (mm)
16 16 0.3 1.2
20 20 0.3 1.2
25 25 0.3 1.2
32 32 0.3 1.3
40 40 0.4 1.4
50 50 0.5 1.4
75 75 0.7 1.6
90 90 0.9 1.8
110 110 1.0 2.2
125 125 1.2 2.5
140 140 1.3 2.8
160 160 1.5 3.2
180 180 1.7 3.6
200 200 1.8 4.0
225 225 2.1 4.5
250 250 2.3 5.0
280 280 2.6 9.8
315 315 2.9 11.1
355 355 3.2 12.5
400 400 3.6 14.0
450 450 4.1 15.6
500 500 4.5 17.5
560 560 5.0 19.6
630 630 5.7 22.1
710 710 6.4 24.9
800 800 7.2 28
900 900 8.1 31.5
1000 1000 9.0 35.0
1) Outside diameter of the pipe shall be taken as the average of two

measurements taken at right angles for pipes up to 110 mm dia.
Alternatively and for higher sizes, the diameter shall be measured preferably
by using a flexible Pi tape or circometer, having an accuracy of not less than
0.1 mm.
2) Ovality shall be measured as the difference between maximum outside

diameter and minimum outside diameter measured at the same cross
section of pipe, at 300 mm away from the cut end. For pipes to be coiled,
the ovality shall be measured prior to coiling.
8
6.1.2 Wall thickness:
The wall thickness shall be measured by a dial Vernier or ball ended
micrometer. The minimum & maximum wall thickness of pipes of PE 63, PE 80
and PE 100 grade material shall be as given in following table 6, 7 and 8
respectively.
Table 6. Wall thickness of pipes for material grade PE 63.
All dimensions in mm.
Nominal Wall thickness of pipes for pressure ratings of
Diameter
DN PN 2.5 PN 4 PN 6 PN 10 PN 12.5 PN 16
Mi Max Min Max Min Max Min Max Min Max Min Max
n. . . . . . . . . . . .
16 - - - - - - - - 2.2 2.6 2.7 3.2
20 - - - - - - 2.3 2.8 2.7 3.2 3.4 3.9
25 - - - - 2 2.4 2.8 3.3 3.4 4 4.2 4.8
32 - - - - 2.3 2.7 3.6 4.2 4.4 5 5.4 6.1
40 - - 2 2.4 2.8 3.3 4.5 5.1 5.5 6.2 6.7 7.6
50 - - 2.4 2.9 3.5 4.1 5.6 6.4 6.8 7.7 8.4 9.4
63 2.0 2.4 3 3.5 4.4 5.1 7 7.9 8.6 9.6 10.5 11.8
75 2.3 2.7 3.6 4.2 5.3 6 8.4 9.4 10.2 11.4 12.5 14
90 2.8 3.2 4.3 5 6.3 7.2 10 11.2 12.2 13.6 15 16.7
110 3.4 3.9 5.3 6 7.7 8.7 12.3 13.7 14.9 16.6 18.4 20.4
125 3.8 4.4 6 6.8 8.8 9.8 13.9 15.5 16.9 18.8 20.9 23.2
140 4.3 4.9 6.7 7.6 9.8 11 15.6 17.4 19 21.1 23.4 25.9
160 4.9 5.6 7.7 8.6 11.2 12.5 17.8 19.8 21.7 24 26.7 29.6
180 5.5 6.2 8.6 9.7 12.6 14.1 20.0 22.2 24.4 27 30 33.2
200 6.1 6.9 9.6 10.7 14 15.6 22.3 24.7 27.1 30 33.4 36.9
225 6.9 7.7 10.8 12 15.7 17.5 25. 27.7 30.5 33.7 37.5 41.5
250 7.6 8.6 11.9 13.3 17.5 19.6 27.8 30.8 33.8 37.4 41.7 46.1
280 8.5 9.6 13.4 14.9 19.6 21.7 31.2 34.5 37.9 41.9 46.7 51.6
315 9.6 10.7 15 16.7 22 24.4 35 38.7 42.6 47.1 52.5 58
355 10. 12.1 16.9 18.8 24.8 27.5 39.5 43.6 48 53 59.2 65.3
8
400 12. 14.2 19.1 22.1 28 32.3 44.5 51.4 54.1 62.4 - -
2
450 13. 15.9 21.5 25 31.4 36.3 50 57.7 - - - -
7
500 15. 17.7 23.9 27.6 34.5 40.4 55.6 64.1 - - - -
2
560 17 19.8 26.7 30.9 39.1 45.2 - - - - - -
630 19. 22.2 30 34.7 44 50.8 - - - - - -
1
9
Diameter
DN PN 2.5 PN 4 PN 6 PN 10 PN 12.5 PN 16
Mi Max Min Max Min Max Min Max Min Max Min Max
n. . . . . . . . . . . .
710 21. 25 33.9 39.1 49.6 57.2 - - - - - -
6
800 24. 28.1 38.1 44.1 55.9 64.4 - - - - - -
3
900 27. 31.6 42.9 49.5 - - - - - - - -
3
1000 30. 35.1 47.7 55 - - - - - - - -
3
Diameter
DN PN 6 PN 10 PN 12.5 PN 16
Min. Max. Min. Max. Min. Max. Min. Max.
16 - - - - - - 2.3 2.7
20 - - 1.9 2.3 2.3 2.7 2.8 3.3
25 - - 2.3 2.7 2.8 3.3 3.5 4
32 1.9 2.3 3 3.4 3.6 4.2 4.5 5.1
40 2.3 2.7 3.7 4.3 4.5 5.1 5.6 6.3
50 2.9 3.4 4.6 5.3 5.6 6.4 6.9 7.8
63 3.6 4.2 5.8 6.6 7 7.9 8.7 9.8
75 4.3 4.9 6.9 7.8 8.4 9.4 10.4 11.6
90 5.1 5.8 8.2 9.3 10 11.2 12.5 13.9
110 6.3 7.1 10 11.2 12.3 13.8 15.2 16.9
125 7.1 8 11.4 12.8 13.9 15.5 17.3 19.2
140 8 9 12.1 14.3 15.6 17.4 19.4 21.5
160 9.1 10.2 14.6 16.3 17.8 19.8 22.1 24.5
180 10.2 11.5 16.4 18.3 20 22.8 24.9 27.6
200 11.4 12.7 18.2 20.3 22.3 24.7 27.6 30.6
225 12.8 14.3 20.5 22.8 25 27.7 31.1 34.4
250 14.2 15.8 22.8 25.3 27.8 30.8 34.5 38.2
280 15.9 17.7 25.5 28.3 31.2 34.5 38.7 42.7
315 17.9 20 28.7 31.8 35 38.7 43.5 48
355 20.1 22.3 32.3 35.8 39.5 43.6 49 54.1
400 22.7 26.3 36.4 42.1 44.5 51.4 55.2 63.7
10
Diameter
DN PN 6 PN 10 PN 12.5 PN 16
Min. Max. Min. Max. Min. Max. Min. Max.
450 25.5 29.5 41. 47.4 50 57.7
500 28.3 32.8 45.5 52.5 55.6 64.1
560 31.7 36.7 51. 58.8
630 35.7 41.3 57.3 66.1
710 40.2 46.5
800 45.3 52.3
900 50.1 58.8
1000 56.6 65.3

Diameter
DN PN 10 PN 12.5 PN 16
Min. Max. Min. Max. Min. Max.
16 1.9 2.3
20 1.9 2.3 2.3 2.7
25 1.9 2.3 2.3 2.7 2.9 3.3
32 2.4 2.8 2.9 3.4 3.7 4.2
40 3 3.5 3.7 4.2 4.6 5.2
50 3.7 4.3 4.6 5.2 5.7 6.4
63 4.7 5.3 5.8 6.5 7.1 8.1
75 5.6 6.3 6.8 7.7 8.5 9.5
90 6.7 7.5 8.2 9.2 10.2 11.4
110 8.1 9.1 10 11.2 12.4 13.9
125 9.2 10.4 11.3 12.7 14.1 15.7
140 10.3 11.6 12.7 14.1 15.8 17.6
160 11.8 13.2 14.5 16.1 18.1 20.1
180 13.3 14.8 16.3 18.1 20.3 22.6
200 14.8 16.4 18.1 20.1 22.6 25
225 16.6 18.4 20.4 22.6 25.4 28.1
250 18.4 20.5 22.6 25.1 28.2 31.2
280 20.6 22.9 25.3 28 31.6 35
315 23.2 25.7 28.5 31.5 35.5 39.3
11
Diameter
DN PN 10 PN 12.5 PN 16
Min. Max. Min. Max. Min. Max.
355 26.1 29 32.1 35.5 40 44.2
400 29.5 34.1 36.1 41.8 45.1 52.1
450 33.1 38.3 40.7 47 50.7 58.6
500 36.8 42.5 45.2 52.1 56.4 65
560 41.2 47.6 50.6 58.4
630 46.8 53.5 56.9 65.6
710 52.3 60.3
800 58.9 67.9
900
1000
6.1.3 Length of straight pipe:

The length of straight pipe shall be 5 m to 20 m, as agreed between the
manufacturer and the purchaser.
6.2 Visual Appearance

The Internal and External surfaces of the pipes shall be smooth, clean and
free from grooving and other defects. The ends shall be cleanly cut and shall be
square with axis of the pipes. Slight shallow longitudinal grooves or irregularities
in the wall thickness shall be permissible provided that the wall thickness
remains within the permissible limits.
6.3 Internal Pressure Creep Rupture Test:

When subjected to internal pressure creep rupture test in accordance
with procedure given IS 4984, the pipes under test shall show no signs of
localised swelling, leakage or weeping, and shall not burst during the prescribed
test duration. The temperatures, duration of test and induced stresses for the
test shall confirm to those specified in following table 9.
Table No.9: Requirements of pipe for Internal Pressure Creep Rupture Test
Sr. Test Test Temp. Test duration Induced stress in MPa. for
No. degree (Min. holding PE 63 PE 80 PE 100
Celsius time)
i) Acceptance Test 80 48 3.8 4.9 5.7
12
6.4 Reversion Test
When tested according to the procedure given in IS 4984, value of the
longitudinal reversion shall not be greater than 3 %.
6.5 Overall Migration Test
When tested from a composite sample of minimum 3 pipes as per IS
9845, the overall migration of constituents shall be within the limits stipulated
in IS 10146.
6.6 Density
7328, it shall meet the requirement as given in preceeding para 3.0, (C).
6.7 Melt Flow Rate (MFR)

2530, at 190 degree Celsius with nominal load of 5 kgf, MFR shall be between
0.2 to 1.1 gram /10 Minutes and also shall not differ by more than 30% of the
MFR of the material used in manufacturing pipes.
6.8 Carbon Black Content & Dispersion

2530, carbon black content shall be within 2.5 + 0.5 % and dispersion of carbon
black shall be satisfactory.
7.0 Marking on Pipes

Each pipe shall be indelibly marked in English language at either end of each
pipe. The marking shall show the following.
1. Manufactures name or trademark.
2. Grade of raw material
3. Pressure rating.
4. Nominal diameter
5. Lot/batch No. of manufacturer.
6. BIS certification mark.
7. Third Party Certification mark for each lot
8. Name of Department/Project for which pipes are manufactured.
9. Any other important matter that the manufacturer or purchaser deems fit to be
inscribed.
8.0 Transportation of Pipe:
Following precaution shall be taken during transportation of pipes

 When transporting straight polyethylene pipes, use flat bedded vehicles. The bed
shall be free from nails and other projections. The polyethylene pipes shall rest
uniformly in the vehicle over their long length.
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 The vehicle shall have side supports approximately spaced 2 m apart, and the pipes
shall be secured effectively during the transportation. All posts shall be flat with no
sharp edges. Strapping the pipe bundles during transit may be required to avoid
excessive movement in the truck.
 Polyethylene pipes shall not be transported with other metallic items in the same
vehicle.
 Coiled pipe with outer diameter < 63 mm may be supplied on pallets. The coils
should be firmly strapped to the pallets, which in turn be firmly secured to the
vehicle. Coiled pipe with outer diameter ≥ 63 mm should be supplied individually.
 There should be facilities to ensure that each coil is securely fastened throughout
transit and the un-loading process.
 To save on transport cost nesting of coils/ straight lengths can be considered, if
agreed to between the purchaser and the supplier.
 Pipes manufactured at factory are to be carried to the site of work directly or stacked
suitably and neatly on contractors yard along the alignment/road side/elsewhere
near by the work site or as directed by the Engineer In-Charge.
9.0 Stacking of Pipes at Site

The following precaution shall be taken so as to eliminate potential damage to
pipes and fittings and to maintain maximum safety.
• Pipes must not be stored or transported where they are exposed to heat sources
likely to exceed 60oC.
• Pipes shall be stored such that they are not in contact with direct sunlight,
lubricating or hydraulic oils, petrol, solvents and other aggressive materials.
• Scores or scratches to a depth of greater than 10% or more of wall thickness are not
permissible; any pipes having such defects should be strictly rejected.
• PE pipes should not be subjected to rough handling during loading and unloading
operations. Rollers shall be used to move, drag the pipes across any surface.
• Dragging pipes over rough ground should be avoided.
• Pipe shall be stacked on reasonable flat surface, free from sharp object, stone or
projection likely to deform or damage the pipes.
• Pipes shall not be dropped to avoid impact or bump. If any time during handling or
during installation, any damage, such as gouge, crack or fracture occurs, the pipe
shall be repaired if so permitted by the competent authority before installation.
• During coiling care should be taken to maintain the coil diameter at or above the
specified minimum to prevent kinks. Coiling shall be done when the pipe attains the
ambient temperature from the extruder. In uncoiling or recoiling care should be
taken that sharp objects do not scour the pipe.
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• When releasing coils, it must be remembered that the coil is under tension and must
be released in a controlled manner. The end of the coil should be retained at all
times, then the straps released steadily, one at a time. If the coil has bands at
different layers of the coil, then they should be released sequentially starting from
the outer layers.
10.0 Valves
For PDN work, various Valves as mentioned below are required to be provided on
pipeline at various location.
10.1 Air Valve :

The effect of air valve in the long-distance water pipelines are in the following three
areas: firstly, in the waterfilled stage of the pipeline, filled with water by a certain
velocity, the air valve can discharge the remained gas in the pipe; secondly, at the
normal working stage, the air valve can discharge the small amount of gas gathered
in the pipe timely; finally, during the pump failure or maintenance stages, the air
valve will replenish the gas into the pipe to break the vacuum. According to the
orifice size, displacement and work pressure, air valve is divided into high pressure
trace exhaust valve, low pressure air release valve and combined air valve.
10.2 Scour Valve :

These Valves are generally provided to drainout the pipeline. The exact location of
Scour valves is frequently influenced by opportunities to dispose off the water.
Where the main pipeline crosses a stream or drainage structures, there will usually
be a low point in the line but if the main pipeline goes under the stream or drain,
it cannot be completely drained into the channel. In such a situation it is better to
locate a scour connection at the lowest point that will drain by gravity and provide
for pumping out the part below the drain pipeline.
10.3 Control Valve :
A control valve is a valve used to control fluid flow by varying the size of the flow
passage as directed by a signal from a controller. This enables the direct control
of flow rate and the consequential control of process quantities such
as pressure, temperature, and liquid level.
Common types of control valve are as given below.
A) Sliding Stem
 Globe valve
 Angle body valve
 Angle seat piston valve
B) Rotary
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 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve
11.0 Post-delivery testing of pipes

After delivery of pipes to worksite, additional test, if desired by Engineer-in-
charge, shall be conducted on random samples of pipes collected from site. These test
shall be as per those given in para forgoing No.6.0
12.0 Site Preparation

12.1 Clearing the Site
The Contractor shall clear the entire area required for setting out. All tree
stumps, roots, brushwood, rubbish of all kinds, loose stones and all other
objectionable materials shall be removed by the Contractor. Buried irrigation
pipeline, and other structure, if any, shall be removed by the Contractor. The
ownership of all the usable material, so removed from clearing site and/or
excavation shall rest with the Engineer In-charge. Useful material shall be
stacked as directed. The Contractor shall dispose off all unusful materials as
directed by the Engineer In-charge.
12.2 Demarcation
All materials such as pegs, bamboo’s and strings and templets for
marking out slopes, and labour required for line out should be provided by the
Contractor at his own cost. The center line of excavation shall be clearly marked
by pegs or by stones at each chain or change of direction or at shorter intervals
on curves, in the beginning. The final line out will be done by fixing reference
stone at suitable distances on either side of the center line, beyond the canal
edges so that they are not disturbed during the construction period. The
position of these stones will be marked on the cross section.
12.3 Contractor shall provide and maintain the quarry roads and temporary roads
required for construction activity at his own cost.
12.4 Fixing Permanent Benchmark
(a) Benchmarks fixed by the Survey of India and temporary benchmarks established
by the Engineer In-charge in vicinity of PDN work will serve as control points for
these works. The Contractor shall establish sufficient number of reference
benchmarks for facilitating setting out of work and taking levels for the purpose
of measurements.
(b) Before starting any work, the Contractor shall erect reference benchmarks,
reference lines and check profiles at convenient locations approved by the
Engineer In-Charge. The benchmark concrete block shall be 200mm x200mm
x600mm with 400mm embedded in the firm ground and 200 mm projecting
16
above ground. The word ‘BM’ showing value of R.L. in ‘m’ shall be conspicuously
carved and painted on the benchmark.
(c) The check profile shall be located 30m apart or closer as directed by the
Engineer In-Charge so as to ensure execution of all slopes, steps and elevations
to the profile or profiles indicated in the approved drawings. All important levels
and all control points with respect to benchmarks and reference lines shall be
fixed and correlated by the Contractor. The Contractor is fully responsible for
maintaining all setting out work & Benchmark established by Engineer-In-
charge.
(d) All materials, labour and equipments (theodolites, levels, distometre, etc.) for
setting out works including construction of benchmarks in concrete, reference
lines, check profiles and surveys as may be required at the various stages of
construction shall be supplied by the Contractor at his cost. For this following
numbers of minimum equipments shall be provided and maintained in
good working condition by the Contractor.
1. Total station and its accessories 1 set

2. Theodolites (Accuracy 1 second) 1 No.
3. Levels 2 Nos.
4. Staves 4 Nos.
5. Tapes, chains, ranging rods etc. As required
All equipments shall be of standard and approved make and precision, and
shall be made available in advance of starting of the work. All equipment
shall be maintained, repaired and got tested and certified as and when
required for its accuracy from the standard test houses or from the
manufactures and to the satisfaction of the Engineer-In-Charge.
13.0 Excavation for Pipe Trenches

13.1 Excavation of pipe trenches shall be carried out as per excavation line shown in
the drawing or as directed by Engineer In -charge. Contractor must assume all
responsibility for deductions and conclusion made by him as to the nature of
the materials to be excavated and the difficulties of making and maintaining the
required excavation. The trench width at bottom shall be 300 mm more than
1.5 times outside pipe diameter. In any case trench width shall not be less than
500 mm.
13.2 The usable excavated material available from the excavated trenches (PDN)
shall be used in backfilling. If such usable material is in excess of the requirement
of backfilling, the same shall be deposited in the spoils as and where directed
by the Engineer In-charge. Unusful material from excavation shall be deposited
in spoils as and where directed by Engineer-In-charge.
13.3 Surface or sub-soil water met with during trench excavation (PDN) and
structure excavation shall be diverted to nearby drain/nalla by cutting an open
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channel from trench. When the drain/nalla bed is higher than the sub-soil water
level met with, the bailing out by suitable means of pumping shall be resorted
to for dewatering sub-soil water below the drain/nalla bed level. No distinction
shall be made as to whether the material being excavated is dry, moist, wet or
slushy. The Contractor shall have to excavate the PDN pipe trench and structure
in under water level conditions also i.e. under wet/slushy condition after
providing sufficient arrangement of dewatering. The material excavated under
water level condition which requires intermediate stacking for drying shall have
to be rehandled. No extra payment for efforts for drying out of soil, re-handling
of dry soil, etc. shall be given. No payment for extra efforts for excavation under
this condition shall be made.
13.4 Over excavation performed by the Contractor for any purpose or reason, except
for additional excavation as stated here in above or as may be directed by the
Engineer-In-charge, shall be rectified at the cost of the Contractor. Filling and
compaction for such over excavation using the material as directed by the
Engineer In- Charge shall also be at the cost of the Contractor.
13.5 In the PDN and structure section where expansive type of the soil such as CH
type of soil is encountered and over which PDN cannot be directly laid, the PDN
trench and structure shall be over excavated to the extent as directed by the
Engineer In Charge and such over excavated section shall be filled with suitable
murum type soil to be placed in uniformly compacted layers as directed by the
Engineer In Charge. The over excavation made in such strata, filling by suitable
soil, and watering and compacting such soil will be paid separately under
relevant items. Above provision for over excavating and filling with suitable
murum type or good soil available material shall be applicable in case such
treatment is found essential.
14.0 Laying of Pipes

While laying of HDPE Pipes, all precautions as mentioned in IS 7634 shall be taken.
14.1 Each pipe shall be thoroughly checked for any damages before laying and only
pipes that approved by Engineer-in-Charge shall be laid.
14.2 The pipe line may be laid along side of the trench and jointed there. There after
the jointed pipeline shall be lowered into the trench carefully without causing
undue bending. The pipeline shall be laid inside the trench with a slack of up to
2 m/100 m of pipe line.
14.3 Polyethylene pipes conforming to IS 4984, being black in colour, when subjected
to direct sunlight or warm ambient temperature may become warmer than the
ground temperature. When placed inside the trench, the pipe will contract in
length as it cools to the surrounding soil temperature. If the pipe is connected
to sub-surface structures (such as preset valve, etc) before it is cooled
sufficiently, excessive pull forces could develop. Allow the pipe to cool to
ambient temperature prior to making a connection to an anchored joint.
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14.4 Polyethylene pipe requires no special bed preparation for laying the pipe
underground, except that there shall be no sharp objects around the pipe.
However, while laying in rocky areas suitable sand bedding should be provided
around the pipe and compacted. 100 mm compacted fine sand bedding under
and around the pipe be provided in rocky areas.
14.5 During the pipe laying of continuous fusion jointed systems, due care and
allowance should be made for the movements likely to occur due to the thermal
expansion/contraction of the material. This effect is most pronounced at end
connections to fixed positions (such as valves etc.) and at branch connections.
Care should be taken in fixing by finishing the connections at a time the length
of the pipe is minimal (lower temperature times of the day).
14.6 The flexibility of polyethylene pipes allows the pipe to be cold bend. The fusion
jointed PE pipe is also flexible as the plain Pipe. Thus the total system enables
directional changes within the trench without recourse to the provision of
special bends or anchor blocks. However, the pipe should not be cold bend to a
radius less than that mentioned in IS 7634 (Part-II).
14.7 The Installation of flanged fittings such as connections to sluice/air/gate valves
and hydrant tees etc., requires the use of stub ends (collars/flange adaptors)
complete with backing rings and gaskets. Care should be taken when tightening
these flanges to provide even and balance torque.
Provision should be made at all heavy fittings installation points for supports
(such as anchoring of the flange in the soil) for the flange joint to avoid the
transfer of valve wheel turning torque on to the PE flange joint
14.8 The pipe shall be laid on a stable foundation. Where water is present or where
the trench bottom is unstable, excess water should be removed before laying
the pipe. In case there is a chance of floatation because of likely flood, the pipe
shall be encased with concrete weights as per the buoyancy calculations.
14.9 Under National / State Highways, a concrete / Hume pipe shall be covered over
the pipe.
14.10 Polyethylene pipes are non-metallic, so once buried, metal detector type
locators are ineffective. To facilitate locating a buried PE pipe, metallic locating
tapes or copper wires can be placed alongside the pipe. Locating tapes/wires
are placed slightly above the crown of the pipe before the final back fill.
Because of high integrity of properly made fusion joints, PE pipes can be
used with special installation techniques such as horizontal directional drilling,
pipe bursting, micro tunnelling methods of trench less technologies.
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15.0 Jointing of Pipes
Jointing of pipes should be done as per Procedure mentioned in IS 7634. The
commonly used joints are as follows:
a) Fusion welding:
1) Butt fusion welding;
2) Socket fusion welding;
3) Electro fusion welding;
b) Insert type joints;
c) Compression fittings/push fit joints;
d) Flanged joints
e) Spigot and socket joints.
The detailed Jointing Procedure of above mentioning various joints shall be as
per IS 7634 (Part-II)
15.1 Fusion Welded Joints

The principle of fusion welding is to heat the two pipe surfaces to a
designated temperature and then fuse them together by application of
sufficient force. This force causes the melted materials to flow and mix, there
by resulting in fusion.
Fusion welding of PE pipes must be carried out with welding equipment
having temperature and pressure (where applicable) display arrangements. PE
pipes and PE fittings, to be joined by face-to-face (butt fusion) welding must be
of the same wall thickness and the ends must be cut square. However, in some
cases of fusion, where face-to-face contact is not involved the jointing
pipes/fittings wall thicknesses need not be same. The integrity of the fusion joint
is dependent on the cleanliness, temperature control and designated
equipment that has been properly maintained.
The pipe ends shall be dry and free of dust. Mating surfaces shall be
planed/scraped before fusion to remove surface material as polyethylene (PE)
oxidizes on exposure to air. These prepared (scraped) surfaces should not be
touched, as there is a risk of contamination of the surface, which may affect the
weld efficiency.
15.2 Insert Type Joint
 Insert type of fittings are available in both plastic and metal for use with PE
pipes. These are commonly used for the delivery pipe connections of
bore/tube well pumps.
 In corrosive locations plastic/stainless steel insert fittings are preferred. In
less corrosion conditions gunmetal fittings may be used and in normal or
slightly corrosive environments, brass fittings may be employed. The insert
moulding plastic fittings with metallic inserts are also available. The outer
serrations of PE/metal insert type fittings-slightly over sized-lock into the
pipes to prevent their coming out under sudden pressure surge. The pipe
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bore is expanded by immersion in oil bath (130°C) where the heat of the oil
bath would soften the pipe to enable insertion of fitting.
 This type of jointing is used normally for pipe diameters up to 110 mm and
internal pressure below 0.4 MPa.
15.3 Compression Fittings
 Compression fittings are detachable joints and are made of metal or
plastics [polypropylene (PP)] or a combination of both. Compression
fittings form a tight seal by applying a compressive force to the pipe and
pipe fitting. The fitting is compressed against the pipe with a force
sufficient to eliminate all space remaining in the joint, thus preventing the
fluid from leaking.
 It is critically important to the integrity of the fitting that excessive force is
avoided in tightening the nut. If the fitting is over tightened, the gripper
(clip ring) will deform and cause leaks. Over tightening is the most common
cause of leaks in compression fittings. As a general rule, a compression
fitting should be ‘finger tight’ and then tightened one turn with a wrench.
The fitting should then be tested, and if slight weeping is observed, the
fitting should be slowly tightened a bit more until the weeping stops.
 Compression fittings are especially useful in installations that may require
occasional disassembly or partial removal for maintenance, etc, since
these joints can be detached and re-joined without affecting the integrity
of the joint. They are also used in situations where a heat source, in
particular a heating plate, is prohibited and inside bead formation by butt
fusion is not preferred.
 For coiled polyethylene pipes, of small diameters (Less than 110 mm)
where the working pressure do not exceed 1.6 MPa, jointing by
polypropylene (PP) compression fittings is generally recommended over
fusion jointing.
15.4 Flanged Joints
 These are used for jointing the PE pipes particularly of larger size to valves
and vessels and large size metal pipes, and where non-PE pipes are to be
joined with PE pipes.
 It contains slip-on metallic/polyethylene flanges with collar/stub ends. The
collar/stub end is welded by butt, socket or electro fusion. In case
polyethylene flanges are used a suitable metallic backing plates shall be used
to support the polyethylene flanges so that the bolt force does not deform
the plastic flange. Sealing is improved by incorporating a natural or synthetic
rubber gasket between the flanges.
15.5 Spigot and Socket Joint

 Any joint that permits sliding of the free end (spigot end) inside the socket
with a rubber or suitable gasket, without leakage is called a spigot and socket
joint.
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 The socket (bell) could be an integral part of the pipe at one end or a special
coupler, into which the free ends (spigot ends) of the pipes are pushed to
achieve a water tight joint. Various types of ‘O’ rings are available in the
market and the user may check with the manufacturer about the suitability
of the same as per site conditions.
 These joints are normally weak in longitudinal pull and hence need
anchoring wherever such a tendency of longitudinal pull is likely in the pipe
line.
 This type of joint is best used for non-pressure applications, such as gravity
lines and for encasing cables or smaller diameter pipes.
16.0 Field Testing Of Pipeline System

16.1 The pipeline to be tested shall be filled with water slowly allowing for splurging
the entrapped air. Air valves at high points should be open to allow air to escape
while water is being filled. Before pressure is applied, the pipeline section under
test shall be restrained against movement.
The following procedure needs to be followed for HDPE pipe testing

a) Polyethylene pipelines shall be pressure tested at ambient temperature.
After filling with water the pipeline shall be left to stabilize for a period of 1
hour.
b) Fusion joints may be covered during testing. Flanged joints shall be kept
open for visual inspection. The pipeline shall be filled with water and
pressure tested from the lowest point.
c) During the test period, make-up water is continuously added to maintain
the pressure.
d) The test pressure shall be 1.5 times the rated pressure of pipes or of the
proposed maximum design pressure of the section. Apply the pressure by
continuously pumping at a constant rate.
e) Under no circumstance, air is to be used instead of water for testing.
f) Tests should be performed on reasonable lengths of pipelines. Long lengths
more than 2 000 m may make leak detection more difficult.
g) Acceptance criteria — If the pressure remains steady (within 5 percent of
the target value) for 1½ h, leakage is not indicated.
h) If the test is not complete because of leakage or equipment failures, the test
section shall be depressurized and allowed to relax for at least 8 h, before
starting the next testing sequence.
j) Testing outside the trench is to be avoided, as pipe rupture may involve
safety issues.
16.2 If any leakage is found during testing of pipeline, Contractor will have to attend
the same immediately and rectify at his cost within. If Contractor fails to rectify
the defect, the entire length of pipeline between two adjacent outlets shall be
rejected. If any intermediate payment is made to the Contractor for portion
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under rejection, the same shall be recovered from the outstanding dues of the
Contractor.
17.0 Backfilling of Pipe Trenches
(a) The type of material used for backfilling and the manner of depositing the material,
shall be subject to approval by Engineer-in-Charge.
(b) The backfill material shall be placed to the line and grades as shown on drawings or
as prescribed in this paragraph or as directed by the Engineer-in-Charge.
(c) The backfill material shall be placed carefully and spread in uniform layers of not
more than 15cm thickness, with the first layer watered and compacted by stamping
or by mechanical means. The backfill shall be brought up as uniformly as practicable
on both sides of pipe to prevent unequal loading.
(d) Only soft earth and gravel of good quality free from boulder, roots, vegetable
matters etc. shall be used for refilling trench upto 300mm above top of pipe. If
sufficient quantity of suitable (Sharp edge stone free) excavated earth is not
available, the trench shall be filled by borrowed gravel material upto 300 mm above
top of pipeline. Remaining trench can be filled with available material.
(e) When compacting the soil against steep rock, abutment walls of concrete structures,
rollers shall not be used close to structures as structural damage is very likely more
particularly when structures have not been fully cured. The size and weight of
equipment will depend on nature of material, the height and load assumed in design
of structure. The backfill close to the structure up to the rolled layer shall be
compacted in suitable uniform layers, using pneumatic / hand tampers as
appropriate for dry density at average bulk density (+/- 10%). The moisture content
of the earth fill placed against the rock or the structure shall be on higher/lower side
of OMC by about 2% or so, to allow it to be compacted. Profuse watering shall be
done to pervious materials (sand) before compaction as per instruction of the
Engineer-in-Charge. Compaction at junction of earthwork and backfill around the
structure shall be carried out with special care.
(f) The trench shall be refilled so as to built-up the original ground level.
18.0 Permanent markings of Pipe alignment

18.1 The contractor shall establish the sufficient number of reference blocks on
the alignment of PDN preferably at the interval of 30m or as suitable on the
field boundaries so as they will not be disturbed during the agricultural
activities of the farmers.
18.2 The marking shall be constructed in prefabricated concrete block of size
(15x15x45)CM embeded in concrete block of size (30x30x30)CM. The base of
this block shall be burried in ground projecting only 15cm above the ground
and the base concrete block.
23
18.3 These blocks shall be able to locate the pipeline as and where it is laid all over
the work. The contractor shall mark each block with specific distinct
identification mark.
18.4 The contractor shall show all this blocks jointly to the Engineer in-charge or his
representative, representative of WUA, concern farmers sharing the
boundaries, TPI, any other stake holders in the command.
18.5 Contractor shall maintained these blocks in proper order during operation &
maintenance period of this contract. Any damage done to these blocks for the
reasons whatsoever shall be made good at the cost of contractor.
18.6 The contractor shall submit the location of such blocks with specific
identification marks with schedule on a special command area map.
18.7 The map of marking of the block shall be handed over to WUA while handing
over the command area.
18.8 The Geotagging map showing Latitude and Longitude Value of each apex of
laid pipeline shall be submitted to Department and WUA for future reference.
18.9 The contract shall fix information boards of 1.2 m x 0.9 m size at various location
as directed by Engineer-in-charge. On this boards, salient features of the work
(eg. Pipe diameter, pipe type, discharge, any other specific details suggested by
Engineer-In-Charge) shall be written.
19.0 Third Party Inspection

19.1 Work of PDN shall be inspected, tested and certified by PMC / TPI / QC.
Modalities of PMC / TPI / QC Inspection shall be separately decided and given
by Engineer In-charge.
Project management consultants (PMC) should have approved laboratories
certification or collaboration with N.A.B.L. (National Accreditation Board for
Testing and Calibration Laboratories)
Third party Inspection can be done form any one of the following services
or from any other mutually agreed agency.
1 Engineers India Limited, Mumbai
2 R.I.T.E.S. (Rail India Technical Economics Services) Mumbai
3 S.G.S, Mumbai
4 Visvesvaraya National Institute of Technology, Nagpur
5 VJTI, Mumbai
6 CWPRS (Central Water & Power Research Station), Pune
7 CIPET (Central Institute of Plastics Engineering & Technology)
19.2 Testing of materials

(a) All materials before being utilized in works shall be inspected and tested, by
the Engineer In-charge or his representative/QC. The nature of testing and
periodical intervals at which such testing is to be done etc. shall be as per
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the latest editions of relevant IS Codes and determined by the Engineer In-
charge. The day-to-day and periodical tests to be carried out on materials
mixes and placed concrete, mortar etc. shall be specified by the Engineer In-
charge from time to time and the Contractor shall provide free of cost all
facilities towards collections of samples etc. unless otherwise specified.
Labours for collecting samples and transportation of the samples to quality
control authorities for test shall be provided free cost of by the contractor.
Also electricity, fuel, water curing tank and stores etc shall be provided free
of cost by the contractors.
(b) The materials shall be tested in QC laboratory or at any other place directed
by the Engineer In-charge. The Contractor shall obtain the test results from
the concern authority and the results given by such authorities shall be
considered to determine whether all materials, workmanship are of
respective standard described in contract and in accordance with the
instructions of the Engineer In-charge. The Contractor’s representatives
shall, however, be given access to all operations and tests that may be
carried out as aforesaid so that he may satisfy himself regarding the
procedure and methods adopted. It shall then be the Contractor’s
responsibility to produce on the work, materials and finished item to the
standard as determined by the laboratory tests or to take follow up action
to rectify the quality.
(c) Testing charges for testing of Cement, TMT bars, all types of pipes and
specials including cost of samples and its collection shall be borne by the
Contractor.
(d) The Contractor shall make suitable arrangements to see that one of his
representatives remains present at the time of taking samples and shall
authenticate the facts. If the Contractor, fails to keep his representative
present at site at the time of taking samples or fail to provide required
labours and other equipment to collect the samples, the same shall be taken
by the Engineer In-charge, and the samples selected shall be considered as
authentic. The cost incurred by the Engineer-In-charge when the Contractor
fails to provide required men and materials for collecting samples and or
their transport shall be recovered from the Contractor.
20.0 Quality Control and Quality assurance

20.1 On award of contract, the Contractor will have to provide adequate quality
assurance setup including Quality Assurance Engineer backed with suitable
laboratory assistants, labours and well equipped laboratory for taking necessary
field test required as per specifications and as per instructions of Engineer in
charge.
20.2 Following minimum persons shall be employed by the contractor at work site
for Quality Assurance.
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Sr. No. Personnel with Qualification Nos.
1 Quality Assurance Engineer(Civil One
Engineering Graduate with 2 Year
experience in QA testing and report
generation work)
2 Laboratory Assistants(Twevlth Pass with
Two to Four
Science subject with 2 year experience in
(As per work)
testing of material)
3 Laboratory Attendants Two to Four
(One for each L.A.)
20.3 Following minimum equipments shall be available in the field laboratory setup
by the contractor.
Sr. No. Work Apparatus for Tests
1 Earth Work – Field density, Moisture Content,
Field testing Equipments Sieves for Sand & Metal.
2 Concrete Work - Silt, Gradation, Moisture Content,
Slump, & Cube Moulds, CTM
20.4 It is the responsibility of the contractor to assure the desired quality of
work. Whenever the testing of construction materials, pipes are required as
per the detailed specifications or otherwise required by the Engineer-in-
Charge, the same shall be carried out at the laboratory, selected by the
Engineer-in-Charge at Contractor’s cost. The other tests of mortar, concrete,
sand, coarse aggregates etc. shall be carried out in field laboratory set up by
the contractor in presence of quality control representative at contractors
cost. Contractor shall through this procedure assure the quality of work.
20.5 The materials, mixes and any other arrangements, including labours, shall be
supplied by the contractor. The samples for testing shall be taken in the
presence of Engineer-in-Charge or his representative /QC present on site. The
contractor or his authorized representative shall have a free access in these
laboratories, to get himself satisfied about procedures of testing etc. Even
if the contractor or his representative fails to remain present while
collecting samples or testing, the results will be considered as authentic and
binding on the contractor.
20.6 Contractor shall provide all test reports of material used in the work as desired
from the NABL (National Accreditation Board for Testing & Calibration
Laboratories) approved laboratories and from Quality Control, MERI
laboratories of the WRD. Contractor shall provide periodical quality assurance
report (Weekly/fortnightly/monthly) to Engineer in Charge along with proofs in
support of quality of material brought for the work, the process/ execution of
work is as per specification.
26
20.7 Contractor shall submit the account of all materials brought for the work, which
are necessary for execution of work and any other data necessary to assess the
quality of work.
20.8 If he fails to fulfill the above requirement, the required manpower for testing
and field laboratory with required equipments will be deployed by the Engineer
in charge and the charges for the same will be recovered from the contractor.
21.0 Operation, Maintenance and Handing over of the System

21.1 The contractor shall operate and maintain the complete pipe distribution
network for the period of 5 (five) years after commissioning. Out of this period,
during last two years the operation of the schemes shall be done by the
contractor jointly along with WUA. On completion of O & M period, the system
shall be handed over to WUA
21.2 During rotation period, once in every year, the Contractor shall perform
hydraulic test to the satisfaction of Engineer In-charge to verify the flow of
designed discharge, detect or confirm any leakage in the system and rectify at
his own cost. The testing shall preferably be conducted jointly with members of
WUA/representative of Engineer In-charge, technical representative of
contractor and any other stake holder.
21.3 On completion of every Irrigation season, the contractor shall flush the pipe line
from its tail flush valve so that any siltation, vegetation or obstruction is cleaned
and pipe is able to flow designed discharge for next season.
21.4 During the O & M period, contractor shall give training to the members of WUA
about O & M of PDN work and its efficient use and protection of the system
from any damages.
21.5 The contractor shall prepare a detail map of the permanent marking along the
alignment of pipe and submit the same to Engineer In-charge. The Engineer In-
charge shall verify and endorse the location of the marking and handover these
signed maps as a permanent record to WUA. Along with this, the detailed
Geotagged map of laid pipeline shall be handed over to WUA.
21.6 In association of the members of WUA, the Engineer In-charge shall confirm the
release of designed discharge through every outlet before handing over. In case
of any short fall or defect, it should be made good from the contractor at his
own cost.
22.0 Mode of Measurement and Payment
22.1 Measurement
The net length of pipes as laid or fixed shall be measured in running meters
correct to a cm. Specials shall be excluded and measured in running meters or
numbers as specified by Engineer-in-charge and paid for separately under the
relevant item. The portion of the pipe overlapped at the joints shall not be
included in the length of pipe work. Excavation, refilling, anchor blocks, thrust
27
blocks wherever required shall be measured and paid for separately under
relevant items of work.
22.2 Payment
The break up to payment for supplying, laying and jointing of pipes shall be as
under:-
A) 80% of the payment will be released after supplying, lowering, laying,
Jointing and third party inspection of pipes in one WUA area.
B) Balance 10% of the payment will be released after satisfactory hydraulic
testing of pipeline and backfilling of trenches.
C) Remaining 10% amount will be withheld and it will be released after
successful maintenance and operation for a period of five years after
commissioning of work of respective WUAs.
The schedule of release of this 10% will be in following manner,
1) After Successful Operation and Maintenance for First year-2%
2) After Successful Operation and Maintenance for Second year-2%
3) After Successful Operation and Maintenance for Third year-2%
4) After Successful Operation and Maintenance for Fourth year-2%
5) After Successful Operation and Maintenance for Fifth year-2%
A certificate regarding smooth working of pipe distribution network from the

Chairman of WUA shall be binding for annual release of this amount.
----------***----------
28
SPECIFICATION FOR
POLYVINYL CHLORIDE PIPES
(PVC)
2020
0
SPECIFICATION FOR POLYVINYL CHLORIDE PIPES (PVC)
1.0 Introduction
Polyvinyl Chloride (PVC) pipes are made by a continuous extrusion process. These
pipes are supplied with plain or with socket-ends. .
The Contractor shall provide on site training on PVC pipe laying, jointing, testing
and maintenance etc.,to the personnel authorized by the Engineer-in-charge. The
contractor should provide technical Manual on PVC pipes including precautions to
be taken during operation of the pipeline.
2.0 Applicable IS Codes

The manufacturing, testing, supplying, laying, jointing and testing at work sites of
PVC pipes shall comply with all currently applicable statutes, regulations, standards
and Codes. In particular, the following standards, unless otherwise specified herein,
shall be referred. In all cases, the latest revision of the Codes shall be referred to. If
mentioned here but pertaining to the use of PVC Pipes form part of these
Specifications.
IS - 4985 Unplastisized PVC pipes for potable water supplies.

IS- 4669 Methods of test for polyvinyl chloride resins
IS-10151 Specification for polyvinylchloride (PVC) & its copolymers for its
safe use in contact with foodstuffs pharmaceuticals& drinking
water.
IS-12235 Methods of tests for unplasticized PVC pipes.
IS 7634 (part- Laying & jointing of UPVC pipes.
3)
3.0 Raw Materials

 Raw material used to manufacture PVC Pipes is polyvinyl chloride.
 The material from which the pipes are made shall consist substantially of
polyvinyl Chloride conforming to I S :10151 to which may be aded only those
additives that are absolutely needed to facilitate the manufacture of the pipe
and the production of sound durable pipe of good surface finish, mechanical
strength and opacity.
 The monomer content (VCM content) in the resin shall be within the limits
specified in IS 10151
 The composition shall be based on PVC resin having a k-value of 64 or greater
when tested in accordance with IS 4669
1
 The addition of the manufacturer’s own rework material is permissible. The
quantity of rework material used is to be declared by the manufacturer. No
other rework material shall be used.

The General manufacturing process of PVC Pipe is as given below.

The PVC resin and the additives are mixed in a heater/cooler mixer to form the PVC
compound.
Formed compound is fed into the extruder through a spiral flow conveyer and hopper
The compound gets molten in the heating zone of the extruder, which is then extruded
into pipes passing through a mandrel/die arrangement. Different mandrel/die
combinations are used for different pipe sizes.
In the vacuum sizing/pressure tank, the dimensions are controlled to within the
tolerances required.
The pipe is then passed through chilled water in a spray tank where the pipe attains its
rigidity.
The extruded pipe is passed through a traction (also called hauling) arrangement to
extract the pipe at a regulated speed. This also controls the dimensions of the pipe.
The pipes are then cut to size in a cutter
One end of the cut pipes is then processed for socketing. The pipe end is heated on a
heating coil and sleeved over a mandrel machined to the socket inner dimensions to get
the socket profile.
4.1 Classification of pipes :

The pipe shall be classified by pressure ratings (working pressures) at 270as follows.
Class of pipe Working pressure (PN)

Class 1 0.25 MPa (2.5 kg/cm2)

All PVC pipes in a single consignment of the same class, same size and manufactured
under essentially similar conditions shall constitute a lot. The number of test samples
to be taken from a lot shall depend on the size of the lot and the outside diameter
of the pipes, and shall be in accordance with following Table No.1.
2
Table No.1 Scale of Sampling for Visual Appearance and Dimensional Requirements
These pipes shall be selected at random from the lot and in order to ensure the
randomness of selection, a random number table shall be used. In the absence of a
random number table, following procedure may be adopted.
Starting from any pipe in the lot, count them as 1, 2,3, etc, upto r and so on, where
r is the integral part of N/n, N being the number of pipes in the lot,and n is the
number of pipes in the sample. Every rth pipe so counted shall be withdrawn so as to
constitute the required sample size.
5.1 The dimensional and visual requirements :

The number of pipes given for the first sample in col 3 of above Table No.1, shall be
taken from the lot and examined for visual and dimensional requirements given in
following para no.6.1 and 6.2. A pipe failing to satisfy any of these requirements
shall be considered as defective. The lot shall be deemed to have satisfied these
requirements, if the number of defectives found in the first sample is less than or
equal to the corresponding acceptance number given in col. 5 of Table 1. The lot
shall be deemed not to have met these requirements, if the number of defectives
found in the first sample is greater than or equal to the corresponding rejection
number given in col 6 of Table 1. If, however, the number of defectives found in the
first sample lies between the corresponding acceptance and rejection numbers
given in col 5 and 6, a second sample of the size given in col 3 shall be taken and
examined for these requirements. The lot shall be considered to have satisfied these
requirements if the cumulative sample is less than or equal to the corresponding
acceptance number given in col 5,otherwise not.
3
5.2 Reversion Test, Vicat softening test, Density, Sulphated ash content test,
Resistant to external blows at 00c , Internal hydrostatic pressure test.
The lot having satisfied dimensional and visual requirements as mentioned in para
5.1 above, shall be tested for Reversion Test, Vicat softening test, Density, Sulphated
ash content test, Resistant to external blows at 00 c , internal hydrostatic pressure
test as mentioned in following para no 6.5 to 6.10. A separate sample size for each
of the test shall be taken as stipulated in following Table no.2 (for Reversion Test,
Vicat softening test and Density test ), Table no.3 (for Sulphated ash content test),
Table no.4 (for Resistant to external blows at 00 c) and Table no.5 (for internal
hydrostatic pressure test),
Table 2 Scale of sampling for Reversion, Vicat Softening Temperature and

Density Test (Reproduced from IS 4985)
Number of Sample Sample Cumulative Acceptance Rejection

pipes in the Lot Number size Sample size Number Number
(1) (2) (3) (4) (5) (6)
Up to 1000 First 5 5 0 2
Second 5 10 1 2
1001 to 3000 First 8 8 0 2
Second 8 16 1 2
3001 to 10000 First 13 13 0 2
Second 13 26 1 2
10001 and First 20 20 0 3
above Second 20 40 3 4
For dn above 110 mm
Up to 3000 Second 3 6 1 2
3001 to 10000 First 5 5 0 2
Second 5 10 1 2
10001 and First 8 8 0 2
Table 3 Scale of sampling for Sulphated Ash Content Test

Number of Sample Sample size Cumulative Acceptance Rejection

pipes in Number Sample size Number Number
the Lot
(1) (2) (3) (4) (5) (6)
Up to First 2 2 0 1
1000 Second 2 4 1 1
Above First 3 3 0 2
10000 Second 3 6 1 2
4
Table 4 Scale of sampling for Resistance to External Blows at 0 0C
Number of Sample Sample size Cumulative Acceptance Rejection

pipes in the Number Sample Number Number
Lot size
(1) (2) (3) (4) (5) (6)
Up to 3000 First 3 3 0 2
Second 3 6 1 2
3001 to 10000 First 5 5 0 2
Second 5 10 1 2
10001 and First 8 8 0 2
NOTE – The number mentioned in col 3 to 6 in the above table represent the number of times the test is to be
carried out and do not represent either the number of pipe samples or number of blows or number of failures.
Table 5 Scale of sampling for Internal Hydrostatic Test

Number of pipes in the Lot Sample size Acceptance Number

(1) (3) (6)
Up to 3000 2 0
3001 to 10000 3 0
10001 and above 5 0
The criteria for conformity of various test mentioned above shall be the same as that
for dimensional and visual requirements as mentioned in above para no. 5.1.

1. Dimensions : Outside diameter, Wall thickness, Length of pipe
3. Opacity
4. Effect on water
5. Reversion test,
6. Vicat’s Softening Test,
7. Density,
8. Sulphated ash content test
9. Resistant to external blows at 00 c
10.Internal hydrostatic pressure test
These test shall be carried out by the agency in the presence of representative
of Engineer In-charge /WRD/QC/TPI.
5
6.1 Dimensions
6.1.1 The mean outside diameter, outside diameter at any point and wall
thickness of pipe shall be as given in following Table no.6
6.1.2 Length :The length of pipe shall be 4,5 or 6 m. The pipe may be supplied
in other lengths, as agreed between the manufacturer and the purchaser

The colour of the pipes shall be light grey. Slight variations in the appearance
of the colour are permitted.
The internal and external surfaces of the pipe shall be smooth, clean and free
from grooving and other defects. Slight shallow longitudinal grooves or
irregularities in the pipe shall be permissible provided the wall thickness
remains within the permissible limits.
6.3 Opacity
The wall of the plain pipe shall not transmit more than 0.2 % of the visible
light falling on it when tested in accordance with IS 12235
6.4 Effect on Water

The pipes shall not have any detrimental effect on the composition of water
flowing through them, when tested as per IS 12235. The limits of all the other
toxic substances shall not exceed the specified limit of 0.01 mg/l
6.5 Reversion Test

When tested by the immersion method prescribed in IS 12235, a length of
pipe 200 ± 20 mm long shall not alter in length by more than 5 percent. In the
case of socket end pipes, this test shall be carried out on the plain portion of
the pipe taken at least 100mm away from the root of the socket.
6.6 Vicat Softening temperature

When tested by the method prescribed in IS 6307, the Vicat softening
temperature of the specimen shall not be less than 80°C.
6.7 Density
When determined in accordance with IS 13360, the density of the pipe shall
be between 1.40 and 1.46.
6
7
6.8 Sulphated ash content test
When tested as per method prescribed in IS 4985, the sulphated ash
content in the pipe shall not exceed 11 percent.
6.9 Resistance to external Blows at 00c

When tested by the method prescribed in IS 4985, the pipe shall have a True
Impact Rate of not more than 10 %
6.10 Internal hydrostatic pressure test

When subjected to internal hydrostatic pressure test in accordance with the
procedure given in IS 12235, the pipe shall not fail during the prescribed test
duration. The temperature of test shall be minimum 27 0c and minimum
holding time (test duration) shall be 1 hour.

Each pipe shall be indelibly marked in English language at intervals of not
more than 3 m . The marking shall show the following.
2. Class of pipe and Pressure rating.
3. Outside diameter
7. Name of Department/Project for pipe which pipes are manufactured.
8. Any other important matter that the manufacturer or purchaser deems fit
to be inscribed.
The class of pipe shall also be colour coded on pipe as mentioned below
Class of pipe Colour

Class 1 Red
Class 2 Blue
Class 3 Green
Class 4 Brown
Class 5 Yellow
Class 6 Black
8.0 Transportation of Pipes

As PVC pipes are durable and light, they are more likely to be mishandled.
Following precautions shall be taken during transportation of pipes.
 When transporting pipes, flat bed vehicles should be used. The bed should be free
from nails and other projections. When practical, pipes should rest uniformly on the
vehicel over the whole length.
8
 The vehicles should have side supports approximately 2 m apart and the pipes
should be secured effectively during transport. All posts should be flat with no sharp
edges.
 When loading spigot and socket pipes, the pipes should be stacked on the vehicle so
that the socket do not take excessive loads.
 Where pipes overhang the vehicle, the amount of overhang should not exceed I m.
 High stiffness pipes should be placed at the bottom of the load and low stiffness
pipes at the top.
 Care should be taken to avoid positioning the pipes near to any exhaust systems or
any other potential hazards such as diesel oil, paints or solvents.
 When pipes are transported in bundles, the bundles should be secured effectively
and off- loaded with due care.
 Mechanical lifting equipment used for lifting pipes and pipe bundles should not
damage the pipe. Fork-lift forks should be flat and protected. Cranes should have
spreader bars. No wire ropes, chains or hooks should be used. Slings should be made
of rope or webbing 7 to 10 cm wide.
 If pipes have been telescoped for transporting, the inner pipes should be removed
first and stacked separately.
9.0 Stacking of Pipes

Following precautions shall be taken so as to eliminate potential damage to
pipes
 Pipes should be stacked on a surface flat and free from sharp objects, stones or
projections in order to avoid deformation or damage. Ends of pipes should be
protected from abrasion and chipping.
 The pipes should be supported evenly over their whole length. The bottom layer of
the stack should be supported on wooden battens of unifrom size, at least 50 mm
wide and placed not more that 2 m apart. The sockets should not bear on the
ground.
 Pipes of different diameters and different pressure classes should preferably be
stacked separately.
 Factory packed pipes should be packed in bundles with timber battens at minimum
three places. These should not be unpacked until required for use.
 It should be necessary to store pipes loose or if they are received loose, care should
be taken to see that each layer of the stack lies alternatively with the sockets on
opposite ends of the stack. The sockets of each pipe must project sufficiently for the
pipes to be supported correctly along the whole length (parallel stacking).
 The sides of the stack must be supported with timber battens to prevent stack
collapse. The side supports should be spaced not more than 3 m apart. The width of
the bottom layer should not exceed 3 m.
 Alternatively, pipes can also be stacked with adjacent layers lying at right angles to
each other (cross stacking).
 Stack height should not exceed 1.5 m in depots and stores or 1 m at construction
sites.
9
 Prolonged exposure of the pipes to sunlight must be avoided. Pipes must be
protected from ultra –violet light (sunlight), which would otherwise cause
discolouration and can reduce the impact strength of the pipe. Suitable protection
by a free-venting cover (canvas tarpaulin or polyethylene sheeting) is recommended
if the total exposed time is likely to exceed 4 weeks.
 Pipes should be stored away from any heat source and should not be in contact with
any other potential hazards such as diesel oils, paints or solvents.
10.0 Valves
pipeline at various locations.
10.1 Air Valve :
The effect of air valve in the long-distance water pipelines are in the following
three areas: firstly, in the water filled stage of the pipeline, filled with water by
a certain velocity, the air valve can discharge the remained gas in the pipe;
secondly, at the normal working stage, the air valve can discharge the small
amount of gas gathered in the pipe timely; finally, during the pump failure or
maintenance stages, the air valve will replenish the gas into the pipe to break
the vacuum. According to the orifice size, displacement and work pressure, air
valve is divided into high pressure trace exhaust valve, low pressure air release
valve and combined air valve.
10.2 Scour Valve :
These Valves are generally provided to drainout the pipeline.The exact location
of Scour valves is frequently influenced by opportunities to dispose off the
water. Where the main pipeline crosses a stream or drainage structures, there
will usually be a low point in the line but if the main pipeline goes under the
stream or drain, it cannot be completely drained into the channel. In such a
situation it is better to locate a scour connection at the lowest point that will
drain by gravity and provide for pumping out the part below the drain pipeline.
A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
10
C) Other
 Pinch valve
 Diaphragm valve

After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge
shall be conducted on random samples of pipes collected from site. These test shall
be as per those given in forgoing para No.6.0

stacked as directed. The Contractor shall dispose off all un useful materials as
12.2 Demarcation
All materials such as pegs, bamboo’s and strings and templets for marking
out slopes, and labour required for line out should be provided by the
Contractor at his own cost. The center line of excavation shall be clearly
marked by pegs or by stones at each chain or change of direction or at
shorter intervals on curves, in the beginning. The final line out will be done
by fixing reference stone at suitable distances on either side of the center
line, beyond the canal edges so that they are not disturbed during the
construction period. The position of these stones will be marked on the cross
section.
(a) Benchmarks fixed by the Survey of India and temporary benchmarks
established by the Engineer In-charge in vicinity of PDN work will serve as
control points for these works. The Contractor shall establish sufficient
number of reference benchmarks for facilitating setting out of work and
taking levels for the purpose of measurements.
above ground. The word ‘BM’ showing value of R.L. in ‘m’ shall be
conspicuously carved and painted on the benchmark.
11
Engineer In-Charge so as to ensure execution of all slopes, steps and
elevations to the profile or profiles indicated in the approved drawings. All
important levels and all control points with respect to benchmarks and
reference lines shall be fixed and correlated by the Contractor. The Contractor
is fully responsible for maintaining all setting out work & Benchmark
established by Engineer-In-charge.
setting out works including construction of benchmarks in concrete,
reference lines, check profiles and surveys as may be required at the various
stages of construction shall be supplied by the Contractor at his cost. For this
following numbers of minimum equipments shall be provided and
maintained in good working condition by the Contractor.

3. Levels 2 Nos.
4. Staves 4 Nos.

13.1 Excavation of pipe trenches shall be carried out as per excavation line shown
in the drawing or as directed by Engineer In -charge. Contractor must assume
all responsibility for deductions and conclusion made by him as to the nature
of the materials to be excavated and the difficulties of making and
maintaining the required excavation. The trench width at bottom shall be 300
mm more than 1.5 times outside pipe diameter. In any case trench width shall
not be less than 500 mm.
shall be used in backfilling. If such usable material is in excess of the
requirement of backfilling, the same shall be deposited in the spoils as and
where directed by the Engineer In-charge. Un useful material from excavation
shall be deposited in spoils as and where directed by Engineer-In-charge.
structure excavation shall be diverted to nearby drain/nalla by cutting an
open channel from trench. When the drain/nalla bed is higher than the sub-
soil water level met with, the bailing out by suitable means of pumping shall
12
be resorted to for dewatering sub-soil water below the drain/nalla bed level.
No distinction shall be made as to whether the material being excavated is
dry,moist, wet or slushy. The Contractor shall have to excavate the PDN pipe
trench and structure in under water level conditions also i.e. under
wet/slushy condition after providing sufficient arrangement of dewatering.
The material excavated under water level condition which requires
intermediate stacking for drying shall have to be rehandled. No extra
payment for efforts for drying out of soil, re-handling of dry soil, etc. shall be
given. No payment for extra efforts for excavation under this condition shall
be made.
13.4 Over excavation performed by the Contractor for any purpose or reason,
except for additional excavation as may be directed by the Engineer-In-
charge, shall be rectified at the cost of the Contractor. Filling and compaction
for such over excavation using the material as directed by the Engineer In-
Charge shall also be at the cost of the Contractor.
type of soil is encountered and over which PDN cannot be directly laid, the
PDN trench and structure shall be over excavated to the extent as directed by
the Engineer In Charge and such over excavated section shall be filled with
suitable murum type soil to be placed in uniformly compacted layers as
directed by the Engineer In Charge. The over excavation made in such strata,
filling by suitable soil, and watering and compacting such soil will be paid
separately under relevant items. Above provision for over excavating and
filling with suitable murum type or good soil available material shall be
applicable in case such treatment is found essential.

While laying of PVC pipes all precautions as mentioned in IS 7634 (part-3) shall be
taken.
 Each pipe shall be thoroughly checked for any damages before laying and only
pipes that are approved by Engineer-in-Charge shall be laid.
 The trench bottom shall be constructed to provide a firm, stable and uniform
support for the full length of the pipeline. There should be no sharp objects that
may cause point loading.
 A minimum bedding thickness of 100 to 150 mm under the pipe shall be provided
by watering and compaction
 For pipes of diameter 100 mm or greater, bell holes in the bedding , under each
socket joint, shall be provided by removing some of the bedding material, to
accommodate the larger diameter of the joint and to permit the joint to be made
properly.
 The pipes shall be preferably laid with the spigots entered into the sockets in the
same direction as the intended flow of water.
13
 To sustain thrust caused by internal pressure, concrete anchor blocks should be
provided at all changes of direction, tees, blank ends, large reductions in diameter
and valves.
 Metal marker tape can be laid into the final backfill to enable electronic location of
the pipe line, if required.

Jointing of pipes shall be done as per procedure mentioned in IS 7634 (Part-3).
Commonly used joints are as follows
a) Solvent welded joints
b) Integral elastomeric sealing ring joints,
c) Mechanical compression joints
d) Flanged joints
e) Screwed or threaded joints, and
f) Union coupled joints
15.1 Solvent welded joints
These are permanent in nature and can withstand axial thrust (end – load bearing)
This technique is used with plain ended pipes with couplers, for pipes with integral
socket as well as with injection mouleded fittings.
Solvent cement consists essentially of a solution of vinyl chloride polymer or

copolymer dissolved in a suitable volatile mixture of organic solvents. The solvent
constituents soften the mating surfaces, which difuse into one anther to from a “cold
weld”. Solvent cement shall confrom to all requirements of IS 14182
PVC solvent cement is quick drying, therefore it shall be applied as quickly and
carefully as possible and in consistence with good workmanship. For larger sizes, it
is advisable for two workers to work simultaneously on the pipe and socket. Within
20 sec after the last application of solvent cement, insert the pipe into socket in a
single steady and every controlled but forceful action.
15.2 Integral elastomeric sealing ring joints,

 Elastomeric sealing ring joints consists of an elastomeric sealing element located in
the socket formed integrally with the pipe or fitting. The sealing element (sealing
ring) is automatically compressed to from a pressure tight seal when the spigot of
the pipe is inserted into the socket.
14
 These joints are non-end load bearing and it is essential to ensure the probability of
joint separation due to axial thrust. Joint separation can be prevented in below
ground applications by incorporating concrete anchor blocks at appropriate places.
 In order to meet water quality and biodegradation requirements, elastomeric

sealing rings are usually made from synthetic materials like ethylene-propylene-
diene (EPDM) copolymer, styrenebutadiene rubber (SBR) or a combination of
synthetic and natural rubber. The material should conform to IS 5382
15.3 Mechanical Compression joints

These are commonly separate fittings made from UPVC or metal and can be in the
form of a coupler for connecting pipes and fittings of the same material and of the
same dimensions, or as an adaptor for connecting components of different
materials and / or dimensions. Generally compressor fittings consists of four main
elements :body,elastomeric sealing rings, backing(compression) rings and bolts.
Both pipe ends should be clean and free from damage before assembly is begun.
Each element is positioned on the pipe separately, centered over the joint and the
sealing rings compressed between the body of the fitting and the pipe by tightening
the back rings. Bolts should not be over tightened.
15.4 Flanged joints

These are used for jointing of UPVC pipes to other pipes, fittings, valves and vessels
made from dissimilar materials, for example metals. The joint is made by
compressing a gasket or elastomeric sealing ring between the mating surfaces of
the flanges.
15
15.5 Screwed or threaded joint
These are similar to the joints used with metal pipes. If the pipe has to be joined by
screw threads, only thick walled pipe should be used and cut with taper threads.
Some manufacturers supply pipes with factory cut threads. Threaded pipes shall not
be subjected to a pressures exceeding two-thirds of the rating for unthreaded pipes.
Injection moulded threaded joints are used for jointing PVC to metal pipes. Injection
moulded threads are less notch sensitive than cut threads.
15.6 Union Coupled joint

This is a form of flanged joint, but the faces are held together by a screwed
connection. A composite metal and PVC socket union is a very satisfactory method
of jointing PVC to screwed metallic fittings.
16.0 Field Testing of Pipeline system.
16.1 General
All pipelines should be tested before being brought into service. The test
should be a hydrostatic test performed by filling the pipeline with water and
raising the pressure to the selected test pressure and maintaining this for a
sufficient period to allow for absorption of water by the pipe material.
`16.2 Site Test Pressure
The test should confirm to following conditions
a) be carried out at ambient temperature;
b) be applied for at least 1 h, but not more than 24 h; and
c) not exceed 1.5 times the maximum rated pressure of the lowest rated
component.
16.3 Test Procedure
 Pipe systems should be hydraulically tested in lengths appropriate to the

diameters and site conditions. Pipelines longer than 800 m may require
testing in sections. Preferably, the length selected for test is between 300
m and 500 m.
 Testing should not take place until any concrete used for anchoring has
fully cured (normally 72 h) and attained its required strength. Solvent
cemented joints must be allowed to harden for a minimum of 24 h before
being subjected to test conditions.
 It is important to provide sufficient backfill over the main barrel of the
pipe, to prevent displacement and to maintain stable temperature
conditions. Leave joints free for inspection.
 The test position should be located at the lowest point of the pipeline
profile to encourage expulsion of air as the pipe is being filled with water.
Adequate air release mechanisms should be located at all high points
along the line.
16
 Before filling the pipeline, all line valves and air venting systems should be
checked open. All air must be removed from the system.
 Fill the system slowly. Water velocity must not exceed 0.6 m/s. Potable
water pipelines should be tested with potable water only. After charging,
close all air valves and check proper action of automatic valves.
 Allow the system to stabilize under a nominal pressure for a minimum of
2 hours. Apply pressure steadily. Observe pressure gauges throughout and
record the rates of pressure increase.
 The pressure should be increased till the specified pressure is reached at
the lowest part of the section. Maintain test pressure at this level, by
additional pumping if necessary, for a period of 1 hour.
 Close all valves and disconnect the pressurizing unit. No further water
should be allowed to enter the system for a further period of 1 hour.
 During the test period, carry out a visual examination of all joints and
exposed connections.
16.4 Leak Detection

 There should be no leakage in any part of the section.
 If there has been a decrease in pressure during this period other than due
to leakage, the original pressure is re-established by injecting a measured
quantity of water into the section.
 The test is considered to be satisfactory if
a) there is no decrease in pressure (a slight rise in pressure is also,
possible due to changes in ambient temperatures),
b) the measured quantity of water required to reinstate the pressure to
the original test pressure is less than the ‘permissible maximum’ Q,
Where,
Q = 4.5 liters per 1.6 km per 25 mm of nominal bore per 30 m head of test
pressure per 24 hours.
 On completion of any test, the residual pressure should be released
slowly and in a carefully controlled manner.
 All defects revealed in the test should be rectified and the procedure
repeated until a satisfactory result is obtained.
 If any leakage is found during testing of pipeline, Contractor will have to
attend the same immediately and rectify at his cost . If Contractor fails to
rectify the defect, the entire length of pipeline between two adjacent
outlets shall be rejected. If any intermediate payment is made to the
Contractor for portion under rejection, the same shall be recovered from
the outstanding dues of the Contractor.
17
(a) The type of material used for backfilling and the manner of depositing
the material, shall be subject to approvalby the Engineer-in-Charge.
(b) The backfill material shall be placed to the line and grades as shown on
drawings or as prescribed in this paragraph or as directed by the Engineer-in-
Charge.
(c) The backfill material shall be placed carefully and spread in uniform
layers of not more than 15cm thickness, with the first layer watered and
compacted by stamping or by mechanical means. The backfill shall be brought
up as uniformly as practicable on both sides of pipe to prevent unequal
loading.
(d) Only soft earth and gravel of good quality free from boulder, roots,
vegetable matters etc. shall be used for refilling of trench upto 300mm above
the top of the pipe. If sufficient quantity of suitable (Sharp edge stone free)
excavated earth is not available, the trench shall be filled by borrowed gravel
material upto 300 mm above top of pipeline. Remaining trench can be filled
with available material.
(e) When compacting the soil against steep rock, abutment walls of
concrete structures, rollers shall not be used close to structures as structural
damage is very likely more particularly when structures have not been fully
cured. The size and weight of equipment will depend on nature of material,
the height and load assumed in design of structure. The backfill close to the
structure up to the rolled layer shall be compacted in suitable uniform layers,
using pneumatic / hand tampers as appropriate for dry density at average
bulk density (+/- 10%). The moisture content of the earth fill placed against
the rock or the structure shall be on higher/lower side of OMC by about 2%
or so, to allow it to be compacted. Profuse watering shall be done to pervious
materials (sand) before compaction as per instruction of the Engineer-in-
Charge. Compaction at junction of earthwork and backfill around the

(15x15x45)CM embedded in concrete block of size (30x30x30)CM. The base
of this block shall be buried in ground projecting only 15cm above the
ground and the base concrete block.
18
18.4 The contractor shall show all this blocks jointly to the Engineer-in-charge or
his representative, representative of WUA, concern farmers sharing the
18.5 Contractor shall maintain these blocks in proper order during operation &
maintenance period of the contract. Any damage done to these blocks for
the reasons whatsoever shall be made good at the cost of contractor.
18.8 The Geotagging map showing Latitude and Longitude value of each apex of
laid pipeline shall be submitted to Department and WUA for future
reference.
18.9 The contract shall fix information boards of 1.2 m x 0.9 m size at various
location as directed by Engineer-in-charge. On this boards, salient features of
the work (eg. Pipe diameter, pipe type, discharge, any other specific details
suggested by Engineer-In-Charge) shall be written.

2 R.I.T.E.S. (Rail India Technical Economics Services)Mumbai
3 S.G.S, Mumbai
5 VJTI, Mumbai
6 CWPRS(Central Water & Power Research Station), Pune

(a) All materials before being utilized in works shall be inspected and tested,
by the Engineer In-charge or his representative/QC. The nature of testing
and periodical intervals at which such testing is to be done etc. shall be as
per the latest editions of relevant IS Codes and determined by the
Engineer In-charge. The day-to-day and periodical tests to be carried out
on materials mixes and placed concrete, mortar etc. shall be specified by
the Engineer In-charge from time to time and the Contractor shall provide
free of cost all facilities towards collections of samples etc. unless
19
otherwise specified. Labours for collecting samples and transportation of
the samples to quality control authorities for test shall be provided free
of cost by the contractor. Also electricity, fuel, water curing tank and
stores etc shall be provided free of cost by the contractors.
(b) The materials shall be tested in QC laboratory or at any other place
directed by the Engineer In-charge. The Contractor shall obtain the test
results from the concern authority and the results given by such
authorities shall be considered to determine whether all materials,
workmanship are of respective standard described in contract and in
accordance with the instructions of the Engineer In-charge. The
Contractor’s representatives shall, however, be given access to all
operations and tests that may be carried out as aforesaid so that he may
satisfy himself regarding the procedure and methods adopted. It shall
then be the Contractor’s responsibility to produce on the work, materials
and finished item to the standard as determined by the laboratory tests
or to take follow up action to rectify the quality.
Contractor.
labours and other equipment to collect the samples, the same shall be
taken by the Engineer In-charge, and the samples selected shall be
considered as authentic. The cost incurred by the Engineer-In-charge
when the Contractor fails to provide required men and materials for
collecting samples and or their transport shall be recovered from the
Contractor.

laboratory assistants, labours and well equipped laboratory for taking
necessary field test required as per specifications and as per instructions of
Engineer in charge.
20
Sr.
Personnel with Qualification Nos.
No.
generation work)
Two to Four
(As per work)
(One for each L.A.)
20.3 Following minimum equipments shall be available in the field laboratory

setup by the contractor.
Sr.
Work Apparatus for Tests
No.
Slump, Cube Moulds&CTM
20.4 It is the responsibility of the contractor to assure the desired qualityof work.
Whenever the testing of construction materials, pipes are required as per the
detailed specifications or otherwise required by the Engineer-in-Charge,the
same shall be carried out at the laboratory, selected by the Engineer-in-
Charge at Contractor’s cost. The other tests of mortar,concrete,sand, coarse
aggregates etc.shall be carried out in field laboratory set up by the contractor
in presence of quality control representative at contractors cost. Contractor
shall through this procedure assure the quality of work.
20.5 The materials,mixes and any other rrangements,including labours,shall be
supplied by the contractor.The samples fo testing shall be taken in the
laboratories,to get himself satisfied about procedures of testing etc. Even if
the contractor or his representative fails to remain present while collecting
samples or testing,the results will be considered as authentic and binding on
the contractor.
20.6 Contractor shall provide all test reports of material used in the work as
desired from the NABL (National Accreditation Board for Testing & Calibration
report (Weekly/fortnightly/monthly) to Engineer in Charge along with proofs
21
in support of quality of material brought for the work, the process/ execution
of work is as per specification.
20.7 Contractor shall submit the account of all materials brought for the work,
which are necessary for execution of work and any other data necessary to
assess the quality of work.
and field laboratory with required equipments will be deployed by the
Engineer in charge and the charges for the same will be recovered from the
contractor.
network for the period of 5 (five) years after commissioning. Out of this
period, during last two years the operation of the schemes shall be done by
the contractor jointly along with WUA. On completion of O & M period, the
system shall be handed over to WUA
designed discharge, detect or confirm any leakage in the system and rectify
at his own cost. The testing shall preferably be conducted jointly with
members of WUA/representative of Engineer In-charge, technical
representative of contractor and any other stake holder.
21.3 On completion of every Irrigation season, the contractor shall flush the pipe
line from its tail flush valve so that any siltation, vegetation or obstruction is
cleaned and pipe is able to flow designed discharge for next season.
21.4 During the O & M period, contractor shall give training to the members of
WUA about O & M of PDN work and its efficient use and protection of the
system from any damages.
21.5 The contractor shall prepare a detail map of the permanent marking along
the alignment of pipe and submit the same to Engineer In-charge. The
Engineer In-charge shall verify and endorse the location of the marking and
handover these signed maps as a permanent record to WUA. Along with this,
the detailed Geotagged map of laid pipeline shall also be handed over to
WUA.
21.6 In association of the members of WUA, the Engineer In-charge shall confirm
the release of designed discharge through every outlet before handing over.
In case of any short fall or defect, it should be made good from the contractor
at his own cost.
22.1 Measurement
correct to a cm. Specials shall be excluded and measured in running meters
or numbers as specified by Engineer-in-charge and paid for separately under
22
the relevant item. The portion of the pipe overlapped at the joints shall not
be included in the length of pipe work. Excavation, refilling, anchor blocks,
thrust blocks wherever required shall be measured and paid for separately
under relevant items of work.
22.2 Payment
The break up to payment for supplying, laying, jointing & hydraulic testing of
pipe line shall be as under:-
jointing and third party inspection of pipes in one WUA area.


----------***----------
23
SPECIFICATION FOR
GLASS FIBER REINFORCED
PLASTIC PIPES (GRP)
2020
0
SPECIFICATION FOR GLASS FIBER REINFORCED PLASTIC PIPES
(GRP)
1.0 Introduction
Glass fibre reinforced Plastic (GRP) pipe is a machine made tubular pipe
containing glass fibre reinforcements embedded in or surrounded by cured
thermosetting resin. The composite structure may contain silicious aggregates,
fillers, thixotropic agents. Thermoplastic or thermosetting liner and/ or surface layer
may be provided for pipe.
As with many other composite materials, the two materials supplement each
other to form a stronger compound. Plastic resins are strong in compressive
loading; the glass fibers are very strong in tension. By combining the two
materials, GRP becomes a material that resists both compressive and tensile forces
very well.
The Contractor shall provide on-site training on GRP pipe laying, jointing,
testing and maintenance etc., to the personnel authorized by Engineer-in-charge.
The contractor should provide technical Manual on GRP pipes including precautions
to be taken during operation of the pipeline.
The manufacturing, testing, supplying, laying, jointing and testing at work

sites of GRP pipes shall comply with all currently applicable statutes, regulations,
standards and Codes. In particular, the following standards, unless otherwise
specified herein, shall be referred. In all cases the latest revision of the Codes shall
be referred to. If requirements of this Specification conflict with the requirements of
the standards / Codes, this Specification shall govern. Others Codes not specifically
1
mentioned here but pertaining to the use of GRP Pipes form part of these
Specifications.
IS 12709 Glass Fiber Reinforced Plastics (GRP) pipes, joints and fittings for
use for Potable water supply
IS 13916 Code of practice for Installation of Glass Fiber Reinforced Plastic
(GRP)piping system
IS 14402 GRP pipes joints and fittings for use sewerage, industrial
waste and water (Other than Potable)
IS 11273 Woven roving fabrics of 'E' glass fiber
IS 11320 Glass fiber rovings for the reinforcement of
polyester and epoxide resin systems
IS 11551 Glass fiber chopped strand mat for the reinforcement of
polyester resin system.
IS 5382 Rubber sealing rings for gas mains, water mains and sewers
3.0 Raw Materials

Raw material use to manufacture the GRP Pipes is Resins, Glass Fiber Reinforcement,
Aggregates, Filler and Additives.
3.1 Resins- Appropriate type of unsaturated polyester resins system confirming to IS 6746
shall be used. The resin and additives used shall be such that they contain no
ingredients, that is, in an amount that has been demonstrated to migrate into water
in quantities that are considered to be toxic.
3.2 Glass Fiber Reinforcement- Glass fiber reinforcement shall be commercial grade E type
(i.e which does not contain more than 1% by mass of alkali )and shall conform to IS
11273, IS 11320 or IS 11551 as appropriate.
3.3 Aggregates- Silicious sand of size range between 0.05mm and 0.8mm may be
incorporated in composite structure.
3.4 Filler- Inert Fillers (with particle size below 0.05mm) may be incorporated either on
their own or with aggregates.
3.5 Additives- Additives may be incorporated for modifying the properties of the resin.

The General requirement relating to the manufacture of GRP pipes shall be
conforming to IS-12709 and IS 11273 .
4.1 There are 3 basic methods of GRP Pipe manufacturing.
a. The Filament Winding Method
2
b. The Hand Lay-up Method
c. The Centrifugally Cast Method
a. The Filament Winding Method
In this, there are 2 different methods as given below.
i. The Discontinuous (also known as the Dual Helical Filament Winding
Method) The resin-impregnated continuous fiber rovings are wound at a
controlled helix angle in each selected direction on a removable mandrel.
ii.The Continuous filament winding method. Using the continuous advancing
mandrel process a very compressed laminate is created that maximizes the
contribution from the three basic raw materials glass-fiber, resin and sand.
b. The Hand Lay-up Method

It is a 100% manual operation and used for manufacturing GRP Pipes of very
small diameters. Hand lay-up typically achieves the best overall strength in
irregular shapes and has a higher overall corrosion resistance than filament
wound pipe. The difference between the above two techniques is the
orientation and layering of the glass fibers. Hand lay-up method utilizes woven
glass rovings as opposed to continuous glass rovings.
c. The Centrifugally Cast method
Multi-End rovings going through a chopper and resin are sprayed into a
rotating, cylindrical, metal mould. The resin impregnates the reinforcement
under the effect of the centrifugal force and forms, after polymerization, a
cylindrical structure. Centrifugal casting is particularly well suited for
producing structures with large diameters. The pipe wall is built up from the
outside inwards in a rotating mould. Once all the materials have been fed into
the mould, the speed of rotation is increased. High centrifugal forces up to 75
g (g-force) press them against the mould wall. Any trapped gas is fully vented
and the raw materials are condensed to a maximum, creating a high quality,
very solid and void free pipe wall. In the final step of production, the pipe is
heated to cure (the resin hardens).
4.2 Classification Of Pipes:-
The pipes are classified on the basis of pressure rating & stiffness class.
4.2.1 Pressure Class (PN) : Pressure classes of pipes are 5 namely PN3, PN6, PN9,
PN12 and PN15 correspond to the working pressure rating of 300, 600, 900,
1200 and 1500 KPa respectively.
4.2.2 Stiffness Class (SN) : Four Stiffress classes of pipes are 4 namely A,B,C, and D
correspond to minimum pipe Stiffness valve of 62,124, 248 and 496 kPa
respectively at 5 % deflection.
3
All pipes of same pressure class, stiffness Class and produced under relatively
uniform composition and condition of manufacture shall constitute a lot One pipe
selected at random from a lot shall be checked for conformance to the
dimensions,
workmanship, pipe stiffness, Hydraulic test, longitudinal strength test, hoop tensile
strength test and additional tests to establish potability of water as mentioned in
following para No. 6.0
The lot shall be declared as conforming to the requirements of the specification, if
the sample pipe meets the requirements of all the tests, otherwise not.

Pipe selected as per sampling criteria mentioned in earlier para 5.0 are subject
to following tests before delivery from factory
1. Dimension: Inside diameter, Outside diameter, Length of Pipe, Out of
Squareness of Pipe, Wall thickness.
2. Workmanship
3. Pipe Stiffness
4. Hydraulic test
5. Longitudinal Strength Test.
6. Hoop Tensile Strength Test.
7. Tests to establish potability of water
6.1 Dimensions
a. Inside Diameter
Inside diameters of pipes shall be within the range given in following Table
No.1 and shall meet the tolerance as specified in this table
4
Table 1 Specified Inside Diameters and Tolerances
All dimensions in millimeters.
Nominal Diameter, Inside Diameter Range, ID Tolerances on
DN Declared ID
Min Max
200 196 204 +/-1.5
250 246 255 +/-1.5
300 296 306 +/-1.8
350 346 356 +/-2.0
400 396 408 +/-2.4
450 446 459 +/-2.7
500 496 510 +/-3.0
600 596 612 +/-3.6
700 695 714
800 795 816 +/-4.2
900 895 918
1000 995 1020
1100 1095 1120
1200 1195 1220
1300 1295 1320
1400 1395 1420 +/-5.0
1500 1495 1520
1600 1595 1620
1800 1795 1820
2000 1995 2020
2200 2195 2220
2400 2395 2420
2600 2595 2620 +/-6.0
2800 2795 2820
3000 2995 3020
b. Outside Diameter
The Outside diameter of pipes shall be as given in following Table No.2,
subject to tolerance as specified in this table.
5
Table No.2 Specified outside diameters and Tolerances
Sr. Nominal Outside diameter Outside Tolerance
No. (DN) mm Diameter (OD)
1 200 208 + 2.0
2 250 259 + 2.1
3 300 310 + 2.3
4 350 361 + 2.4
5 400 412 + 2.5
6 450 463 + 2.7
7 500 514 + 2.8
8 600 614 + 3.0
9 700 718 + 3.3
10 800 820 + 3.5
11 900 922 + 3.8
12 1000 1024 + 4.0
13 1100 1126 + 4.3
14 1200 1228 + 4.5
15 1300 1330 + 5.0
16 1400 1432 + 5.0
17 1500 1534 + 5.0
18 1600 1636 + 5.5
19 1800 1840 + 6.0
20 2000 2044 + 6.5
21 2200 2248 +7.0
22 2400 2452 +7.5
23 2600 2656 +8.0
24 2800 2860 +8.5
25 3000 3064 +9.0
c. Lengths- Pipes shall be in effective lengths of 6m, 9m and 12m. The

tolerance on lengths shall be within ± 25mm.
d. Out of Squareness of Pipe: All points around each end of a pipe unit shall
fall within ± 6.5 mm or ± 0.5 percent of the nominal diameter of the pipe
whichever is greater, to a plane perpendicular to the longitudinal axis of
the pipe when measured in accordance with of IS 12709
d. Wall thickness- The minimum wall thickness at any point shall not be less
than the wall thickness specified in the manufacturer's data sheets. The
manufacturer shall ensure that the wall thickness specified in his data sheet
shall be such as to satisfy the inside or outside diameters as per Table No.1
or Table No.2 above.
6
6.2 Workmanship
Workmanship shall be in accordance with good practice as listed in following
Table No. 3 and shall meet the acceptance criteria specified.
Table no.3 : Allowable Defects (Reproduced from IS 12709)
Name Definition Visual Acceptance Levels
Chip A small piece broken off an edge or Maximum dimension of

surface break 6.5 mm
Crack An actual separation of the laminate, None
visible on opposite surfaces and
extending through the thickness
Crack, surface Crack existing only on the surface of a Maximum length, 6.5 mm
laminate
Crazing Fine cracks at or under the surface of Maximum dimension of
a laminate crazing, 2.5 mm
Delamination edge Separation of the layers of material at Maximum dimension, 6.5 ,,
the edge of a laminate
Delamination Separation of the layers of material None
internal in a laminate
Dry-spot Area of incomplete surface film Maximum diameter, 14 mm
where the reinforcement has not
been wetted with resin
Foreign Metallic particles included in a Maximum dimension, 1.5mm
inclusion(metallic) laminate which are foreign to its
composition
Foreign inclusion Non-metallic particles of substance Maximum dimension, 1.5
(non-metallic) included in a laminate which seem mm
foreign to its composition
Fracture Rupture of laminate surface without Maximum dimension, 29 mm
complete penetration
Air bubble (void) Air entrapment within and between Maximum diameter, 3.0 mm
the plies of reinforcement, usually
spherical in shape
Blister Rounded elevation of the surface of a Maximum diameter, 6.5 mm;
laminate, with boundaries that may height from surface not to be
be more or less sharply defined, outside drawing tolerance
somewhat resembling in shape a
blister on the human skin
6.3 Pipe Stiffness
Each length of pipe shall have sufficient strength to exhibit the minimum pipe
stiffness (F/ ∆y) specified in the following Table 4 when tested in accordance
with of IS 12709
7
Table No.4 Pipe Stiffness at 5 percent Deflection
Pipes shall be capable of being deflected to level 'X' with no visible

damage in the test specimen evidenced by surface cracks and to level 'Y' with
no indication of structural damage as evidenced by inter laminar separation,
separation of the liner or surface layer (if incorporated) from structural wall,
tensile failure of the glass fiber reinforcement and fracture or buckling of the
pipe wall, when tested in accordance with IS 12079
Deflection Ring deflection without Damage or Structural Failure, in

Level Percent for pipe of Stiffness Class
A B C D
Level, X 18 15 12 9
Level, Y 30 25 20 15
6.4 Hydraulic test :-

Each length of pipe of nominal diameter up to 1400 mm shall withstand without
leakage or cracking the internal hydrostatic test pressures as specified in following
Table 5 for the applicable class when tested in accordance with IS 12709. For pipes
of nominal diameter above 1400 mm, the frequency of hydrostatic leak tests shall be
as agreed between the manufacturer and the purchaser.
Table 5 Hydrostatic Test Pressures
Pressure Class Hydrostatic Test Pressure
PN kPa
3 600
6 1 200
9 1 600
12 2 400
15 3 000
8
6.5 LONGITUDINAL STRENGTH TEST
For size up to DN 600 the pipe shall withstand, without failure, the beam loads specified in
following Table 6, when tested in accordance with IS 12709. For pipes sizes larger than DN
600 and alternatively for smaller sizes adequate beam strength shall be demonstrated by
tensile tests conducted in accordance with IS 12709 for pipe wall specimens oriented in the
longitudinal direction. The minimum tensile strength specified in Table 6 shall be complied
with
Table 6 Beam Strength Test Loads and Longitudinal Tensile Strength of Pipe Wall
Nominal Beam Load Minimum Longitudinal Tensile Strength in kN/m of
Diameter P Circumference for Pressure Class of
DN kN PN 3 PN 6 PN 9 PN 12 PN 15
200 3.6 102 102 102 102 102
250 5.3 102 102 102 102 110
300 7.1 102 102 102 112 136
350 9.8 102 102 115 131 154
400 13.3 102 102 130 149 177
450 17.8 102 102 138 159 185
500 19.6 102 102 154 176 205
600 28.5 102 123 184 211 246
700 - 102 140 215 246 280
800 - 102 154 231 265 304
900 - 105 174 260 298 341
1 000 - 122 193 290 331 379
1 100 - 127 212 318 363 417
1 200 - 140 212 318 363 431
1300 - 152 226 345 393 498
1 400 - 164 247 371 423 504
1500 - 175 265 397 454 540
1 600 - 185 283 423 484 574
1 800 - 206 318 476 545 646
2 000 - 231 329 492 563 678
2 200 - 254 361 541 619 745
2 400 - 280 394 591 676 813
2 600 - 301 427 640 732 880
2 800 - 326 459 690 789 949
3 000 - 347 492 739 844 1 016
6.6 Hoop tensile strength test :-

All pipes manufactured as per this specification shall meet or exceed the hoop
tensile strength shown for each size and class in following table No.7, when tested
in accordance with IS 12709.
9
Table 7 Minimum Hoop Tensils Strength of Pipe Wall
Nominal Minimum Hoop Tensile Strength in kN/m Width of
Diameter Circumference for Pressure Class
(mm)
PN 3 PN 6 PN 9 PN 12 PN 15
200 122 244 366 488 610
250 152 304 456 608 760
300 182 364 546 728 910
350 213 426 639 852 1 065
450 243 486 729 972 1 215
500 304 608 912 1 216 1 520
600 365 730 1 095 1 460 1 825
700 425 850 1 275 1 700 2 125
800 486 972 1 458 1 944 2 430
900 547 1 094 1 641 2 188 2 735
1 000 608 1 216 1 824 2 432 3 040
1 100 668 1 336 2 004 2 672 3 340
1200 729 1458 2187 2916 3645
1300 790 1580 2369 3159 3949
1 400 851 1 702 2 553 3 404 4 255
1500 911 1823 2734 3645 4556
1 600 972 1 944 2 916 3 888 4 860
1 800 1 094 2 188 3 282 4 376 5 470
2 000 1 215 2 430 3 645 4 860 6 075
2 200 1 337 2 674 4 011 5 348 6 685
2 400 1 458 2 916 4 374 5 832 7 290
2 600 1 580 3 160 4 740 6 320 7 900
2 800 1 701 3 402 5 103 6 804 8 505
3 000 1 823 3 646 5 469 7 292 9 115
6.7 TESTS TO ESTABLISH POTABILITY OF WATER

Pipe specimen shall be subjected to tests specified below as per IS 12709 in
order to establish the suitability of these pipes for use in carrying potable water.
i) Smell of the extract,
ii) Clarity of the colour of the extract,
iii) Acidity and alkality,
iv) Global migration,
v) UV absorbing material,
vi) Heavy metals,
vii) Unreoctd monomers (styrens)
viii) Biological tests
10
3. Pressure rating.
4. Nominal diameter
9. Any other important matter that the manufacturer or purchaser deems fit to
be inscribed.

Following precaution shall be taken during transportation of pipes.
 The truck used for transportation of the GRP pipes shall be exclusively used for
GRP pipes only with no other material loaded – especially no metallic, glass
and wooden items. The truck shall not have sharp edges that can damage the
Pipe.
• Pipes manufactured at factory are to be carried to the site of work directly or
stacked suitably and neatly on contractors yard along the alignment/road
side/elsewhere near by the work site or as directed by the Engineer In-Charge.
• All pipe sections and fittings shall be supported on timber saddles spaced at 4
m centers with a maximum overhang of ‘2 m. Stock height should not generally
exceed 2 m. Pipes shall be strapped to the vehicle over the support points
using non-metallic pliable straps or ropes only.
• All the pipes and fittings shall be lifted with pliable straps, slings or ropes. These
may be canvas or polyester belts with a minimum width of 10 cms or nylon
ropes with a minimum diameter of 30 mm. Steel cables or ropes shall not be
used for lifting and transportation of pipe. Ropes shall not pass through the
section of the pipe end to end.
• Straight continuous lengths of pipe may be lifted at one point. However, owing
to its very smooth surface it is usually safer for the pipe to be lifted at two
points.
• Pipes assemblies fabricated in multiple sections or special places shall be lifted
with two or more lifting points.
• Pipes shall not be dropped to avoid impact or bump. If any time during handling
or during installation, any damage, such as gouge, crack or fracture occurs, the
pipe shall be repaired if so permitted by the competent authority before
installation.
11
9.0 Stacking Of Pipes
Following precaution shall be taken so as to eliminate potential damage to
pipes.
 Pipes and fittings with diameters of less than 1.0 m may be stored directly on
sandy soil, the ground should be flat and free from sharp, projection and
stones/rocks bigger than 40 mm in diameter or of other potentially damaging
debris.
 Pipes with diameters greater than 1.0 m may be stored on their delivery
cradles at a maximum distance of 6 m c/c.
• If the surface is not flat or is sloping, then all the pipes shall be checked to
prevent rolling.
• All rubber rings, gaskets and other items shall be stored in a cool, dry and dark
place to avoid damage of any kind.
10.0 Valves
10.1 Air Valve :
three areas: firstly, in the waterfilled stage of the pipeline, filled with water by a
certain velocity, the air valve can discharge the remained gas in the pipe;
maintenance stages, the air valve will replenish the gas into the pipe to break the
vacuum. According to the orifice size, displacement and work pressure, air valve
is divided into high pressure trace exhaust valve, low pressure air release valve
and combined air valve.
10.2 Scour Valve :
These Valves are generally provided to drainout the pipeline. The exact location
of Scour valves is frequently influenced by opportunities to dispose off the water.
Where the main pipeline crosses a stream or drainage structures, there will
usually be a low point in the line but if the main pipeline goes under the stream
or drain, it cannot be completely drained into the channel. In such a situation it
is better to locate a scour connection at the lowest point that will drain by gravity
and provide for pumping out the part below the drain pipeline.
A) Sliding Stem
12
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve

After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge,

stacked as directed. The Contractor shall dispose off all unuseful materials as
12.2 Demarcation
All materials such as pegs, bamboo’s and strings and templets for marking
out slopes, and labour required for line out should be provided by the
marked by pegs or by stones at each chain or change of direction or at shorter
intervals on curves, in the beginning. The final line out will be done by fixing
reference stone at suitable distances on either side of the center line, beyond
the canal edges so that they are not disturbed during the construction period.
The position of these stones will be marked on the cross section.
number of reference benchmarks for facilitating setting out of work and taking
levels for the purpose of measurements.
13
reference lines shall be fixed and correlated by the Contractor. The Contractor
is fully responsible for maintaining all setting out work & Benchmark
established by Engineer-In-charge.

3. Levels 2 Nos.
4. Staves 4 Nos.

of the materials to be excavated and the difficulties of making and maintaining
the required excavation. The trench width at bottom shall be 300 mm more
than 1.5 times outside pipe diameter. In any case trench width shall not be
less than 500 mm.
where directed by the Engineer In-charge. Unuseful material from excavation
14
channel from trench. When the drain/nalla bed is higher than the sub-soil
water level met with, the bailing out by suitable means of pumping shall be
resorted to for dewatering sub-soil water below the drain/nalla bed level. No
distinction shall be made as to whether the material being excavated is dry,
moist, wet or slushy. The Contractor shall have to excavate the PDN pipe
trench and structure in under water level conditions also i.e. under
wet/slushy condition after providing sufficient arrangement of dewatering.
The material excavated under water level condition which requires
intermediate stacking for drying shall have to be rehandled. No extra payment
for efforts for drying out of soil, re-handling of dry soil, etc. shall be given. No
payment for extra efforts for excavation under this condition shall be made.
except for additional excavation as may be directed by the Engineer-In-charge,
shall be rectified at the cost of the Contractor. Filling and compaction for such
over excavation using the material as directed by the Engineer In- Charge shall
also be at the cost of the Contractor.

While laying of pipes all precautions as mentioned in IS 13916 shall be taken
 Laying should take place only after the trench and the surface supporting the
pipes have been prepared according to the specification.
 For a coupling type of joint, two rubber ring gaskets are first fixed into the groove
inside the coupling and then the coupling is to be fixed at the coupling area of
the pipe and pipe is to be lowered in the trench.
 Before placing a pipe in the trench, it is necessary to clean any remains of earth,
sand or mud from the inside of the socket and from the opposite end bearing the
rubber ring gasket/packing. When cleaning has taken place, run a hand around
inside the socket to ensure that there are no residues of hardened resin which
can be removed readily with a chisel. It is also necessary to check that the groove
has an even depth and has not been damaged for instance, during carriage of
handling.
15
 Place the pipe in the trench, taking care to dig a small hollow at each end so that
the groove and the socket are well separated from the sand and gravels in the
bottom of the trench.
 Anchor the first pipe section laid according to the method described and leave
its ends free along a space enough for insertion of the next section and for
checking. Place the next pipe section in the trench and leave enough space for
the operator to be free to move and to work between the two pipe sections so
as to carry out the cleaning and checking operations.
 Clean the coupling area of the joint once more with a cloth and also clean the
flared portion of the lead-in using suitable lubricant.
 Clean the groove again, take the rubber ring gasket and lubricate it by running it
between the hands and checking at the same time, it being in good condition. It
should be ensured that every portion of the ring or inside of the socket must not
lacks lubricant as it will impair good insertion of the pipe.
 For socket and spigot type of joint, pass the rubber ring under the pipe until it
settles into the groove, then pull it forcibly upwards and follow the ring with the
hands so that three quarters of it is positioned in the groove, then lift the ring
above the upper generating line of the pipe forcibly and then release it so that it
falls into the groove thus being freed of any twists.
 Run the hands around the pipe to check that the whole of the packing is in its
seating and, in the case of large diameter pipes, smear lubricant again above the
inserted rubber ring gasket/packing.
 Align and bring together the two pipe sections until rubber ring touches the
flared portion of the lead-in. When this has taken place, examine the position of
the ring and above all, ensure that there are no sand or other foreign bodies
present.
 Fit the socket onto the spigot very slowly dwelling half way along the coupling
area, and check the position of the packing visually.
 Proceed with the joint until the socket is halted by the abutment ledge. The next
pipe section should not be fitted until the previous pipe section has been
anchored with an overlay of sand.
 Check the rubber ring gasket/packing after the joint has been coupled. This check
must always be carried out and is performed with a blade of steel or of another
metal having a thickness of 0.4/0.5 mm, a width of 15 mm and any length greater
than 200 mm, the blade being inserted into the annular space between the
socket and the spigot. This check should be conducted along all the
16
circumference where the packing is compressed so as to ensure that the rubber
ring has a homogeneous depth and is therefore correctly positioned in its seating.
If the ring is found to be seated differently at one point than other points or if
there is any doubt, disconnect the joint, check the rubber ring and replace it if it
shows any permanent signs of faulty seating, check once more the coupling area
of the joint, the flared, lead-in of the socket and the groove on the spigot. When
re-inserting the pipe section, take extra care to align the pipes perfectly. When
uncoupling pipe sections, never use chains or steel cables in direct contact with
the pipes.
 Check once again the position of the ring with the blade.
 RCC thrust blocks should be provided at bends and at places of reductions in
cross section to take care of thrust.
 The pipe should be uniformly and continuously supported throughout its whole
length with firm stable bedding material. The bedding material should be placed
so as to give complete contact between the bottom of the trench and pipe. The
bedding material should be watered and compacted.
15.0 Jointing Of Pipes

Jointing of pipe should be done as per procedure mentioned in IS 13916.
The pipe shall have a jointing system that shall provide for fluid tightness for the
intended service conditions. Selections of different pipe jointing system depend
upon location, site and working condition, pressure and flow of liquids. The
commonly used joints are as follows.
15.1 Unrestrained Pipe Joint
These pipe joints are capable of withstanding internal pressure but not
longitudinal forces. These joints however can accommodate the linear
variation of the pipe due to temperature variation. These joints are of 3 types
as mentioned below.
15.1.1 Spigot and Socket Joint with Single Water Tight-Rubber Ring Gasket/Packing
This type of joint enables a pipeline to be laid speedily and is suitable for low
(up to 3 PN) pressures in buried lines.
17
15.1.2 Spigot and Socket Joint with Double Watertight Rubber Ring Gasket/Packing
This joint is made with double rubber ring and is suitable for high pressure (3
PN and above).
15.1.3 Double Socket Coupling Joint with Watertight Rubber Ring Gasket/Packing
This joint is made with double socket type coupling and is suitable both for
low and high pressure.
The pipe to be connected shall be placed on the bed with the sufficient
distance from previously joined pipe to allow lowering of pipe with the
coupling into position. Pull the pipe with coupling on to the previously laid
pipe by means of jack after clamping the pipe. Care shall be taken in the
alignment of the coupling with pipes.
15.2 Restrained Pipe Joint

The restrained type pipe joint is capable of withstanding internal pressure and
longitudinal forces. For pipe line consisting of restrained joints only, expansion
joints shall be provided in consultation with the manufacturer of pipe fittings.
These joints are of 5 types as mentioned below.
15.2.1 Spigot and Socket Joint with Gluing

This joint is suitable for underground applications under conditions of normal
outside loads and low pressures. It is easy to make and enables a high laying
speed to be reached. The glueing is to be done by polyester cement or any
other adhesive suitable for a hydraulic and mechanical seal.
18
15.2.2 Spigot and Socket Joint with Glue and Overlay
This type of joint is suitable both for low and high pressure. Gluing the joint
should be done with suitable adhesive and overlay with the same material as
used in pipe. The minimum thickness of overlay shall be 1.5 times of the
thickness of pipes.
15.2.3 Butt Joint

It is used for running pipes and for the connection of straight runs to fittings
(reduction, elbows, flanges, etc). The minimum thickness of joint ‘t’ shall not
be less than the thickness of pipe. Width of overlay shall not be less than ten
times the thickness of the pipe on either side of the joint.
19
15.2.4 Flanged Joint
The flange joint is used for connecting the valves, pumps or any other
apparatus or pipes of different materials. The flanged joint is made from the
same material as the pipe.
15.2.5 Steel Collar on GRP Pipe for Flanged Connection

A steel loose flange is slipped on to a GRP pipe and then a hand layup collar is
done. The steel collar may now be connected to any flanged connection.

16.1 General
16.2 Site Test Pressure

The test pressure shall be 1.5 times the rated pressure for a given class of pipes
or fittings. The test pressure shall be maintained for a period of 24 hours.
20
16.3 Test Procedure
The following procedure is recommended for GRP pipe testing:
a) GRP pipelines shall be pressure tested at ambient temperature.
b) During the test period, make-up water is continuously added to maintain
the pressure.
16.4 Leak Detection
Each full length of pipe section, fittings and joints shall be leak tight. If any
leakage is found during testing of pipeline, Contractor will have to attend
immediately and rectify at his cost. If Contractor fails to rectify the defect, the
entire length of pipeline between two adjacent outlets shall be rejected and
not accepted. The payment shall not be made for the rejected work. If any
intermediate payment is made to the Contractor for portion under rejection,
the same shall be recovered from the outstanding dues of the Contractor.

(a)The type of material used for backfilling and the manner of depositing the
material, shall be subject to approval by the Engineer-in-Charge.
drawings or as prescribed in this paragraph or as directed by the
Engineer-in-Charge.
(c) The backfill material shall be placed carefully and spread in uniform layers of
not more than 15cm thickness, with the first layer watered and compacted by
stamping or by mechanical means. The backfill shall be brought up as
uniformly as practicable on both sides of pipe to prevent unequal loading.
matters etc. shall be used for refilling of trench upto 300mm above the top of
the pipe. If sufficient quantity of suitable (Sharp edge stone free) excavated
earth is not available, the trench shall be filled by borrowed gravel material
upto 300 mm above top of pipeline. Remaining trench can be filled with
available material.
(e) When compacting the soil against steep rock, abutment walls of concrete
structures, rollers shall not be used close to structures as structural damage
is very likely more particularly when structures have not been fully cured. The
size and weight of equipment will depend on nature of material, the height
and load assumed in design of structure. The backfill close to the structure up
to the rolled layer shall be compacted in suitable uniform layers, using
pneumatic / hand tampers as appropriate for dry density at average bulk
density (+/- 10%). The moisture content of the earth fill placed against the
rock or the structure shall be on higher/lower side of OMC by about 2% or so,
to allow it to be compacted. Profuse watering shall be done to pervious
materials (sand) before compaction as per instruction of the Engineer-in-
Charge. Compaction at junction of earthwork and backfill around the
21
(15x15x45) CM embedded in concrete block of size (30x30x30)CM. The base
reference.

3 S.G.S, Mumbai
5 VJTI, Mumbai
22
per the latest editions of relevant IS Codes and determined by the
Engineer In-charge. The day-to-day and periodical tests to be carried out
on materials mixes and placed concrete, mortar etc. shall be specified by
the Engineer In-charge from time to time and the Contractor shall provide
free of cost all facilities towards collections of samples etc. unless
otherwise specified. Labours for collecting samples and transportation of
the samples to quality control authorities for test shall be provided free of
cost by the contractor. Also electricity, fuel, water curing tank and stores
etc shall be provided free of cost by the contractors.
(b) The materials shall be tested in QC laboratory or at any other place
directed by the Engineer In-charge. The Contractor shall obtain the test
results from the concern authority and the results given by such
authorities shall be considered to determine whether all materials,
workmanship are of respective standard described in contract and in
accordance with the instructions of the Engineer In-charge. The
Contractor’s representatives shall, however, be given access to all
operations and tests that may be carried out as aforesaid so that he may
satisfy himself regarding the procedure and methods adopted. It shall then
be the Contractor’s responsibility to produce on the work, materials and
finished item to the standard as determined by the laboratory tests or to
take follow up action to rectify the quality.
Contractor.
considered as authentic. The cost incurred by the Engineer-In-charge
when the Contractor fails to provide required men and materials for
collecting samples and or their transport shall be recovered from the
Contractor.
23
Engineer in charge.

generation work)
Two to Four
(As per work)
(One for each L.A.)
20.3 Following minimum equipments shall be available in the field laboratory setup by
the contractor.
Slump, Cube Moulds & CTM
Engineer-in-Charge at Contractor’s cost. The other tests of mortar,
concrete, sand, coarse aggregates etc. shall be carried out in field
laboratory set up by the contractor in presence of quality control
representative at contractors cost. Contractor shall through this procedure
assure the quality of work.
20.5 The materials, mixes and any other arrangements, including labours, shall
be supplied by the contractor. The samples for testing shall be taken in the
presence of Engineer-in-Charge or his representative /QC present on site.
The contractor or his authorized representative shall have a free access
in these laboratories, to get himself satisfied about procedures of testing
etc. Even if the contractor or his representative fails to remain present
while collecting samples or testing, the results will be considered as
authentic and binding on the contractor.
24
desired from the NABL (National Accreditation Board for Testing &
Calibration Laboratories) approved laboratories and from Quality Control,
MERI laboratories of the WRD. Contractor shall provide periodical quality
assurance report (Weekly/fortnightly/monthly) to Engineer in Charge along
with proofs in support of quality of material brought for the work, the
process/ execution of work is as per specification.
contractor.

period, during last two years the operation of the schemes shall be done by
the contractor jointly along with WUA. On completion of O & M period, the
system shall be handed over to WUA
his own cost. The testing shall preferably be conducted jointly with members
of WUA/representative of Engineer In-charge, technical representative of
alignment of pipe and submit the same to Engineer In-charge. The Engineer
In-charge shall verify and endorse the location of the marking and handover
these signed maps as a permanent record to WUA. Along with this, the
detailed Geotagged map of laid pipeline shall also be handed over to WUA.
at his own cost.
25
22.1 Measurement
22.2 Payment

----------***----------
26
Specifications for
Pre-stressed Concrete Non Cylinder
Pipes (P.S.C.)
2020
0
Specifications for Prestressed Concrete Non-Cylinder (P.S.C.) Pipe
1.0 Introduction
Prestressed Concrete Non-Cylinder Pipe is suitably compacted concrete core
longitudinally prestressed with pretensioned high tensile steel wire embedded In the
concrete, circumferentially prestressed and coated with cement mortar or concrete
to protect the circumferential prestressing wire, to withstand internal pressure and
external design loads.
The Contractor shall provide on-site training on PSC pipe laying, jointing, testing and
maintenance etc., to the personnel authorized by Engineer-in-Charge. The contractor
should provide technical Manual on PSC pipes including precautions to be taken
during operation of the pipeline.

The manufacturing, testing, supplying, laying, jointing and testing at work sites of PSC
pipes shall comply with all currently applicable statutes, regulations, standards and
Codes. In particular, the following standards, unless otherwise specified herein, shall
be referred. In all cases the latest revision of the Codes shall be referred to. If
mentioned here but pertaining to the use of PSC Pipes form part of these
Specifications.
1
IS: 784 Specifications for Prestressed Concrete pipes (Including specials)
IS:783 Code of practice for Laying of Concrete Pipes
IS:3597 Methods of Test for Concrete pipes
IS 1785 Specifications for Plain Hard –drawn steel wire for Prestressed
Part 1, Part 2 Concrete.
IS 383 Specifications for coarse and fine aggregates from natural sources for
concrete
IS 1566 Specifications for Hard Drawn Steel Wire for Concrete Reinforcement
IS:2062 Specification for steel for General Structural purposes
IS: 5382 Specification of Rubber Sealing Rings for Gas Mains, Water Mains & Sewers
3.0 Raw Materials
Raw materials used to manufacture PSC Pipes are cement, aggregates, water,
admixture, steel reinforcement, steel for specials, rubber sealing rings.
3.1 Cement
The cement used in the manufacture of PSC pipes shall conform to one of the
following.
1) 43/53 grade Ordinary Portland Cement conforming to IS:8112/IS 12269
2) Rapid Hardening Portland cement conforming to IS: 8041
3) Portland Slag cement (with not more than 50% slag) conforming to IS: 455
4) Sulphate resisting Portland Cement conforming to IS: 12330
3.2 Aggregate
The coarse and fine aggregates shall conform to I.S.383. The maximum size of
aggregate shall not exceed one third the thickness of the pipe or 20mm
whichever is smaller. Silt Content in fine aggregates shall be less than 3
percent. The fineness modulus of aggregates for coating shall be between 2.6
to 3.2.
3.3 Water
The water used in the preparation of concrete mix shall be clean and free from
harmful or injurious compounds such as acids, alkali, oil, organic material or
other substances and shall conform to the requirements of mixing water as per
IS : 456.
2
3.4 Admixtures
Admixtures may be used with the approval of the purchaser. However, use of
any admixture containing chlorides in any form shall be prohibited The
admixtures shall conform to IS 9103.
3.5 Steel wires
Prestressing steel wire shall conform to IS 1785.
3.6 Steel for Specials
Steel plates for Specials shall conform to IS: 2062
3.7 Rubber Sealing Rings
• Rubber sealing ring shall comply with IS 5382
• Every ring shall be visually checked for defects, particularly at joints.
• Sealing ring shall be clearly labeled in bundle to indicate type of joints,
internal diameter and name of manufacturer.
• Not more than 2 splices in each ring shall be permitted.
• Composition of natural rubber in sealing ring shall be as per IS 784.
The Manufacturing of pipes and specials for PSC pipes shall be as per IS 784. The
mould and method of manufacture of pipe shall be such that the form and
dimensions of the finished pipe conform to IS 784 and the surface and edges of the
pipes are clean and true. Various steps involved in pipe manufacturing process are as
given below.
 Longitudinal prestressing of high tensile wires.

 Placing of concrete in the core either by the centrifugal method or vertical
casting method ( Minimum cement content - 350 kg/m3 , Maximum W/C ratio
- 0.5 and Minimum compressive strength at 28 days - 40 N/mm2) with a smooth
inner surface.
 Spiral winding of high tensile wires on cured concrete core.
 Rich cement mortar out coating (cover coating) on pipe.(minimum cement
content- 540kg/m3, minimum water cement ratio– 0.27, minimum compressive
strength of cement mortar at 28 days-35 N/mm2).
 Curing of pipe.
3
Cross-section of PSC Pipe Joint
PSC pipe shall be designed to withstand the combined effects of internal water
pressure & external loads. Design of PSC pipes shall be site specific as internal water
pressure will depend on pipe profile whereas external loads will depend on maximum
cover (i.e. overburden) over the crown of pipe.
All the pipes manufactured under relatively similar conditions in respect of raw-
materials and processing operation, shall be grouped together to constitute a lot Each
lot shall be taken separately for sampling and evaluation, for conformity to the
requirements of IS 784. Scale of sampling shall be as given in following Table No.1.
4
Table No.1 Scale of Sampling and No. of Acceptable defective tests
Pipe selected as per sampling criteria mentioned in above para 5.0 are subject to
following tests before delivery from factory.
1) Dimensions - Length, Internal diameter, Core thickness, straightness and finish.

2) Hydrostatic Factory Test
3) Permeability Test on Coating
4) Mortor soundness test
6.1 Dimensions
6.1.1 Length -
Length of Pipe shall be 2 to 6m. For pipes upto and including 300mm
diameter, the length shall not be more than 3m.
6.1.2 Nominal internal diameter of the pipe and minimum core thickness
shall be as per following Table No. 2
5
Table 2 Nominal Internal Diameter and Minimum Core Thickness of Pipes
Nominal Internal Minimum Core Nominal Internal Minimum Core
Diameter of Pipe Thickness Diameter of Pipe Thickness
(mm ) (mm ) (mm ) (mm )
200 35 1300 75
250 35 1400 75
300 35 1500 80
350 35 1600 85
400 35 1700 90
450 35 1800 95
500 35 1900 100
600 40 2000 105
700 40 2100 110
800 45 2200 115
900 55 2300 120
1000 60 2400 125
1100 65 2500 130
1200 70 - -
Note : Core thickness for pipes needs to be designed based on internal hydrostatic pressure and
external overburden, based on actual site conditions.
6.1.3 The deviation from straight line taken between two points one meter
apart, along the pipe barrel shall not exceed 5mm.
6.1.4 The pipe shall be free from local depressions or bulges greater than
5mm extending over a length, in any direction.
6.2 Hydrostatic Factory Test

The pipe shall be subjected to hydrostatic test after coating in accordance with
IS 3597. For this test, the pipe is placed on a hydrostatic test bench, filled with
water and pressure has to be raised slowly up to designed factory test
pressure. Pressure shall be maintained by pumping water as per IS 3597.
The pipe must not show leakage. Damp or wet patches shall be accepted. If
the pipe fails to pass the test, it can be cured or repaired to improve its water
tightness and then retested. In case the pipe does not stand the rated internal
pressure, it shall be accepted for lower pressure to which it withstands, at the
discretion of Engineer-in-charge, provided all other requirements are
conforming to this standard.
6
6.3 Permeability Test on Coating
The drop of water level, in the specimens of pipes selected when tested
according to method described in IS 3597 shall not exceed 2 cm3 at the end of
two hours and the final permeability between fourth and fifth hours shall not
exceed 0.3 cm3. When a higher result is obtained, the test shall be repeated
on twice the number of pipes originally tested and the lot shall be accepted, if
all pipes pass the test. Where retest is not satisfactory, all pipes from that lot
may be tested individually and only those with satisfactory results shall be
accepted. No additional treatment of any type shall be allowed on the pipe
before permeability test is taken. The test shall be done immediately after the
hydraulic factory test. In case this is done later, then the pipe has to be kept
wet for 48 hrs prior to test.
6.4 Mortor soundness test
After the mortar coating is cured and prior to transport, the coating on each
pipe shall be checked for delamination and hollows by tapping the exterior
with hammer having head of mass of not more than 0.5 kg. Any hollows or
drumming areas detected by sounding shall be repaired by approved method.

Each pipe shall be indelibly marked in English language at either end of each pipe.
The marking shall show the following.
2. Pressure rating.
3. Nominal diameter
inscribed.

 The vehicle shall have side supports approximately spaced 2m apart, and the pipes
shall be secured effectively during the transportation. All posts shall be flat with
no sharp edges.
 A pipe section must be rolled or otherwise moved, such operation shall be done
slowly and with every reasonable precaution against damage. Any portion of the
lining, coating that may become damaged shall be repaired with polymer Mortar.
 Pipes manufactured at factory are to be carried to the site of work directly or
stacked suitably and neatly along the alignment/ road side/elsewhere near by the
work site, as directed by the Engineer.
7
 All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded
carefully using crane/ tripod. No unloading using crow bars or on tires will be
allowed in any case. Rubber belt may be used instead of crow bars or chains.
 Pipes should be loaded at the works for transportation, either by rail or by road, in
such a way that they are secure and that no movement can take place on the
vehicle during transit. The same care is needed if pipes are to be transferred from
one vehicle to another, however, short the journey may be.
 Un-loading of pipes should be carried out by means of chain block with shear legs
or crane of adequate capacity, using properly designed slings and spreader beams
or specially designed lifting beams. Slings should be placed around the
circumference of the pipe and should not be threaded through the pipe bore' as
the latter method may damage the jointing surfaces. For the same reasons, hooks
located in the ends of the pipes should not be used.
Typical Lifting beam
9.0 Stacking Of Pipes at Site

Following precaution shall be taken while stacking of pipes so as to eliminate
potential damages to pipes.
 Pipes may be placed directly on the ground provided it is reasonably level and
free from rocks and other projections.
 Stacking in tiers is permissible provided timber bearers are placed between
succeeding tiers.
 Rolling down of the stacked pipes must be avoided by providing wedges wherever
required.
 All pipes shall be loaded /unloaded on/from truck by mechanical crane only. No
hook shall be used and nylon tape of sufficient size and width shall be used.
8
10.0 Valves
10.1 Air Valve :
three areas: firstly, in the waterfilled stage of the pipeline, filled with water by
a certain velocity, the air valve can discharge the remained gas in the pipe;
the vacuum. According to the orifice size, displacement and work pressure, air
valve is divided into high pressure trace exhaust valve, low pressure air release
10.2 Scour Valve :
These Valves are generally provided to drainout the pipeline. The exact
location of Scour valves is frequently influenced by opportunities to dispose
off the water. Where the main pipeline crosses a stream or drainage
structures, there will usually be a low point in the line but if the main pipeline
goes under the stream or drain, it cannot be completely drained into the
channel. In such a situation it is better to locate a scour connection at the
lowest point that will drain by gravity and provide for pumping out the part
below the drain pipeline.
A control valve is a valve used to control fluid flow by varying the size of the
flow passage as directed by a signal from a controller. This enables the direct
control of flow rate and the consequential control of process quantities such
A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve

9
12.2 Demarcation
All materials such as pegs, bamboo’s and strings and templets for marking out
slopes, and labour required for line out should be provided by the Contractor
at his own cost. The center line of excavation shall be clearly marked by pegs
or by stones at each chain or change of direction or at shorter intervals on
curves, in the beginning. The final line out will be done by fixing reference
to the profile or profiles indicated in the approved drawings. All important
levels and all control points with respect to benchmarks and reference lines
shall be fixed and correlated by the Contractor. The Contractor is fully
responsible for maintaining all setting out work & Benchmark established by
Engineer-In-charge.
10
3. Levels 2 Nos.
4. Staves 4 Nos.

than 1.5 times outside pipe diameter. In any case trench width shall not be less
than 500 mm.
trench and structure in under water level conditions also i.e. under wet/slushy
condition after providing sufficient arrangement of dewatering. The material
excavated under water level condition which requires intermediate stacking
for drying shall have to be rehandled. No extra payment for efforts for drying
out of soil, re-handling of dry soil, etc. shall be given. No payment for extra
efforts for excavation under this condition shall be made.
11

While laying of PSC pipe, all precaution as mentioned in IS 783 shall be taken.
Concrete pipes have to be properly handled, bedded & back filled, if they have to
carry the full design loads safely.
 Pipes should be lowered into the trench with tackle suitable for the weight of
pipes, such as well designed shear slings with chain block or mobile crane.
 While lifting, the position of the sling should be checked when the pipe is just
clear off the ground to ensure proper balance.
 Laying of pipes shall preferably proceed upgrade of a slope.
 When laying is not in progress, the open end of the pipe line should be fitted
with temporary end-closure. This may make the pipe buoyant in the event of
the trench becoming flooded and any movement of the pipes should be
prevented either by partial refilling of the trench or by temporary strutting.
• When gradient for pipe laying is steeper than 1 in 6, suitable transverse anchor
blocks as specified in IS 783 shall be provided for anchoring of pipeline.
• Expansion joints shall be provided for buried lines at maximum interval of
100m, if rigid joints are used.
• Each pipe shall be thoroughly checked for any damages before laying and only
the pipes which are approved by the Engineer shall be laid.
• Bedding requirements for this pipe are minimal due to rigid nature of pipe.
However, while laying in rocky area, 150 mm compacted fine sand bedding
under and around pipe needs to be provided.
• The trench shall be kept free of water till the jointing has been properly done.
12
15.1 Jointing of pipes shall be done as per procedure mentioned in IS 783. The
sections of the pipe should be jointed together in such a manner that there
shall be as little unevenness as possible along the inside of the pipe. As soon
as joint assembly is complete, the last pipe laid should be firmly restrained in
position until backfilling over it is complete and well compacted.
15.2 The joint are mainly of two types, viz. Rigid joints and Flexible joints.
15.2.1 Rigid joints - In this type of joint, the water seal is effected by cement
mortar or similar material which will not allow any movement between the
two pipes. These joints can be of three types as mentioned below.
I. Socket and Spigot Joint - The annular space between socket and spigot is filled
with cement mortar (1 : 2). This joint is used for low pressure pipe line.
Socket and Spigot Joint
II. Collar Joint - Collars of 15 to 20 cm wide cover the joint between two
pipes. A slightly damp mixtures of cement and sand is rammed with
caulking tool.
Collar Joint ( Rigid )
III. Flush Joint : This joint can be internal or external as given below.
13
(a) Internal flush joint - This joint is generally used for culvert pipes of 900
mm diameter and over. The ends of the pipes are specially shaped to
form a self centering joint with an internal jointing space 1.3 cm wide.
The finished joint is flush with both inside and outside with the pipe
wall. The jointing space is filled with cement mortar mixed sufficiently
dry to remain in position when forced with a trowel or rammer.
Internal flush joint ( Rigid )
(b) External flush joint - This joint is suitable for pipes which are too small
for jointing from inside. Great care shall be taken in handling to .ensure
that the projecting ends are not damaged as no repairs can be readily
effected from inside -the pipe.
External flush joint ( Rigid )
15.2.2 Flexible Joints - In this type of joint, the water seal is effected because
of contact pressure between the sealing rubber ring (or similar material)
and the pipe surface. These are mainly of two types.
14
I. Roll on Joint - A rubber ring ( circular in cross-section) is placed at or near
the end of the spigot and rolls along it as the spigot enters the socket.
Roll on Joint ( Flexible )

II. Confined Gasket - Rubber ring of circular cross -section is held in the
groove formed on the spigot. Sometimes, the cross-section is in the shape
of lip. The lips are opened due to water pressure which ensure water seal.
For assembly of this joint, a lubricant has to be applied to the sliding
surfaces. The lubricant washes off when the pipe is in service.
Confined O-Ring Joint ( Flexible )

15.3 The basic requirements for all types of joints mentioned above are as
enumerated below.
a) cleanliness of all parts, particularly joint surface;
b) correct location of components;
c) centralization of spigot within socket;
d) provision of the correct gap between the end of the spigot and the back
of the socket ( for rubber ring joint) to ensure flexibility at each joint;
and
e) any lubricant used shall be approved as to composition and method of
application.
15
16.0 Field Testing of Pipeline system
16.1 All pipelines should be tested before being brought into service. The test
16.2 AS per I.S.784, the test pressure should be 1.5 times design working pressure.
16.3 Test procedure- Each section should be properly sealed off, preferably with
special stop secured by adequate anchors. The thrust on the stop ends should be
calculated on the full socket internal diameter and the anchors designed to resist
it. It may often be economical to provide .a concrete anchor block of couple of
pipes laid and earth tamped around which has subsequently to be demolished
rather than risk movement of the stop ends during testing. Hydraulic jacks may be
inserted between the temporary anchors and stop ends in order to take up any
horizontal movement of the temporary anchor.
All permanent anchors should be in position and, if of concrete, should have
developed adequate strength before testing begins. The section under test should
be filled with water, taking care that all air is displaced either through vents at the
high points, or by using a swab.
After filling, the pipeline should be left under operating pressure for a
period in order to achieve conditions as stable as possible for testing. The length
of this period will depend upon many factors such as initial permeability,
absorption, movement of the pipeline under pressure and the quantity of air
trapped.
More water should be pumped in from a calibrated container until the
required test pressure is reached. The test pressure should be maintained
throughout the test by means of continuous pumping. The rate of loss of water
from the container should be determined at regular intervals. The generally
accepted standard for absorbent pipelines such as PSC pipes is 3 liter per
millimeter of pipe diameter per kilometer of pipeline per day for each 30 meter
head-of pressure applied.
16.4 Leak Detection -If the test is not satisfactory, the fault should be found and
rectified. Where there is difficulty in locating a fault, the section under test
should be subdivided and each part tested separately.
If any leakage is found during testing of pipeline, Contractor will have
to attend the same immediately and rectify at his cost. If Contractor fails to
rectify the defect, the entire length of pipeline between two adjacent outlets
shall be rejected. If any intermediate payment is made to the Contractor for
portion under rejection, the same shall be recovered from the outstanding
dues of the Contractor.
16.5 Final Testing – After all sections have been jointed together on completion of
section testing, a test on the complete pipeline should be carried out. This test
should be carried out at a pressure not less than the working pressure of the
pipeline, care being taken to ensure that the pressure at the lowest point in the
pipeline does not exceed the maximum. During the test, an inspection should be
made of all work which has not been subjected to sectional tests.
16
(a) The type of material used for backfilling and the manner of depositing the
(b) The backfill material shall be placed to the line and grades as shown on drawings
or as prescribed in this paragraph or as directed by the Engineer-in-Charge.
(c) The backfill material shall be placed carefully and spread in uniform layers of
not more than 15cm thickness, with the first layer watered and compacted by
stamping or by mechanical means. The backfill shall be brought up as uniformly
as practicable on both sides of pipe to prevent unequal loading.
earth is not available, the trench shall be filled by borrowed gravel material upto
300 mm above top of pipeline. Remaining trench can be filled with available
material.
structures, rollers shall not be used close to structures as structural damage is
very likely more particularly when structures have not been fully cured. The size
and weight of equipment will depend on nature of material, the height and load
assumed in design of structure. The backfill close to the structure up to the
rolled layer shall be compacted in suitable uniform layers, using pneumatic /
hand tampers as appropriate for dry density at average bulk density (+/- 10%).
The moisture content of the earth fill placed against the rock or the structure
shall be on higher/lower side of OMC by about 2% or so, to allow it to be
compacted. Profuse watering shall be done to pervious materials (sand) before
compaction as per instruction of the Engineer-in-Charge. Compaction at
junction of earthwork and backfill around the structure shall be carried out with
special care.

17
18.4 The contractor shall show all this blocks jointly to the Engineer-in-charge or his
maintenance period of the contract. Any damage done to these blocks for the
18.8 The Geotagging map showing Latitude and Longitude value of each apex of laid
pipeline shall be submitted to Department and WUA for future reference.

19.1 Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities
of PMC / TPI / QC Inspection shall be separately decided and given by Engineer
In-charge.
Third party Inspection can be done form any one of the following services or
from any other mutually agreed agency.
3 S.G.S, Mumbai
5 VJTI, Mumbai
periodical intervals at which such testing is to be done etc. shall be as per the
latest editions of relevant IS Codes and determined by the Engineer In-charge.
The day-to-day and periodical tests to be carried out on materials mixes and
placed concrete, mortar etc. shall be specified by the Engineer In-charge from
time to time and the Contractor shall provide free of cost all facilities towards
collections of samples etc. unless otherwise specified. Labours for collecting
samples and transportation of the samples to quality control authorities for
test shall be provided free of cost by the contractor. Also electricity, fuel,
18
water curing tank and stores etc shall be provided free of cost by the
contractors.
Contractor.
considered as authentic. The cost incurred by the Engineer-In-charge when
the Contractor fails to provide required men and materials for collecting
samples and or their transport shall be recovered from the Contractor.

Engineer in charge.

1 Quality Assurance Engineer(Civil Engineering One
Graduate with 2 Year experience in QA testing and
report generation work)
2 Laboratory Assistants(Twevlth Pass with Science
Two to Four
subject with 2 year experience in testing of
(As per work)
material)
(One for each L.A.)
19


Engineer-in-Charge at Contractor’s cost. The other tests of mortar,
concrete, sand, coarse aggregates etc. shall be carried out in field
laboratory set up by the contractor in presence of quality control
representative at contractors cost. Contractor shall through this procedure
assure the quality of work.
contractor or his authorized representative shall have a free access in
these laboratories, to get himself satisfied about procedures of testing
etc. Even if the contractor or his representative fails to remain present
while collecting samples or testing, the results will be considered as
contractor.
20
from any damages.
at his own cost.

22.1 Measurement
21
22.2 Payment

----------***----------
22
SPECIFICATIONS FOR
PRE-STRESSED CONCRETE
CYLINDER PIPE (PCCP)
2020
0
SPECIFICATIONS FOR PRESTRESSED CONCRETE CYLINDER PIPES
(PCCP)
1.0 Introduction
The Prestressed Concrete Cylinder Pipe (PCCP) comprises of a welded sheet steel
cylinder with steel socket and spigot rings welded to its ends, lined with concrete
suitably compacted and circumferentially prestressed to withstand internal pressure
and external design load. PCCP pipe is subsequently coated with cement mortar to
protect the steel cylinder and prestressing wires.
The Contractor shall provide on-site training on PCCP pipe laying, jointing, testing and
maintenance etc., to the personnel authorized by Engineer-in-Charge. The contractor
should provide technical Manual on PCCP pipes including precautions to be taken
during operation of the pipeline.

The manufacturing, testing, supplying, laying, jointing and testing at work sites of PCCP
mentioned here but pertaining to the use of PCCP Pipes form part of these
Specifications.
IS: 784 Specifications for Prestressed Concrete pipes (Including specials)

IS 1785 Specifications for Plain Hard –drawn steel wire for Prestressed
Part 1&2 Concrete.
IS 383 Specifications for coarse and fine aggregates from natural sources for
Concrete
IS: 7322 Specifications for Specials for Steel Cylinder Reinforced Concrete pipes
1
3.0 Raw Materials
Raw materials used to manufacture PCCP Pipes are cement, aggregates, water,
admixture, steel reinforcement, steel for cylinders and specials.
3.1 Cement
The cement used in the manufacture of PCCP pipes shall conform to one of the
following.
1) 43/53 grade Ordinary Portland Cement conforming to IS:8112/IS 12269
3) Portland Slag cement (with not more than 50% slag) conforming to IS: 455
4) Sulphate resisting Portland Cement conforming to IS: 12330
3.2 Aggregate
whichever is smaller. Silt Content in fine aggregates shall be less than 3 percent.
The fineness modulus of aggregates for coating shall be between 2.6 to 3.2.
3.3 Water
other substances and shall conform to the requirements of mixing water as per
IS : 456.
3.4 Admixtures
3.5 Steel reinforcement
3.5.1 Prestressing steel wire shall conform to IS 1785.
3.5.2 Untensioned reinforcement may consist of MS bars conforming to IS432
or HYSD bar conforming to 1786
3.6 Steel plates for Cylinders, Joint rings and Specials

Steel plates for cylinders, joint rings and Specials shall conform to IS: 2062
2
The Manufacturing of pipes and specials for PCCP pipes shall be as per IS 784.
The mould and method of manufacture of pipe shall be such that the form and
dimensions of the finished pipe conform to IS 784 and the surface and edges of
the pipes are clean and true. Various steps involved in pipe manufacturing
process are as given below.
 Fabrication & hydrostatic testing of steel cylinder as per required size

 Welding of steel socket and spigot rings to end of steel cylinder.
 Placing of concrete in the core either by the centrifugal method or vertical
casting method ( Minimum cement content - 350 kg/m3, Maximum W/C
ratio - 0.5 and Minimum compressive strength at 28 days, - 40 N/mm2)
 Spiral winding of high tensile wires on cured concrete core.
 Rich cement mortar out coating (Cover coating) on pipe. ( minimum cement
content- 540kg/m3 , minimum water cement ratio – 0.27, minimum
compressive strength of cement mortar at 28 days-35 N/mm2).
 Curing of pipe.
Cross-section of PCCP Pipe Joint
PCCP pipe shall be designed to withstand the combined effects of internal water
pressure & external loads. Design of PCCP pipes shall be site specific as internal water
pressure will depend on pipe profile whereas external loads will depend on maximum
cover (i.e. overburden) over the crown of pipe.
3
requirements of IS 784 Scale of sampling shall be as given in following Table No.1.
1) Steel Cylinder Test.
5) Mortar soundness test
6.1 Steel Cylinder Test: During manufacturing, each steel cylinder with steel and spigot rings
welded on shall be subjected to water pressure which stresses the steel to at least 140
N/mm2but not more than 175 N/mm2. While under stress, the assembly, especially
welds shall not show any leakage. If any leakage is found, assembly shall be repaired
and whole assembly retested.
6.2 Dimensions
6.2.1 Length -
Length of Pipe shall be 2m to 6m. For pipes upto and including 300mm
diameter, the length shall not be more than 3m.
6.2.2 Nominal internal diameter of the pipe and minimum core thickness shall be as
per following Table No. 2
4
Table 2 Nominal Internal Diameter and Minimum Core Thickness of Pipes
Nominal Internal Minimum Core Nominal Internal Minimum Core
Diameter of Pipe Thickness Diameter of Pipe Thickness
(mm ) (mm ) (mm ) (mm )
200 35 1300 75
250 35 1400 75
300 35 1500 80
350 35 1600 85
400 35 1700 90
450 35 1800 95
500 35 1900 100
600 40 2000 105
700 40 2100 110
800 45 2200 115

900 55 2300 120
1000 60 2400 125
1100 65 2500 130
1200 70 - -
6.2.3 Minimum wall thickness of steel cylinders shall be 1.6 mm

6.2.4 The minimum thickness of plates for steel socket & spigot joint rings shall be as per
5
Table No.3 : Minimum wall thickness of joint rings.
Nominal Internal Diameter Minimum wall thickness of joint rings.
(mm ) (mm )
200 5.0
250 5.0
300 5.0
350 5.0
400 5.0
450 5.0
500 5.0
600 5.0
700 5.0
800 5.0
900 5.0
1000 7.0
1100 7.0
1200 8.0
1300 8.0
1400 8.0
1500 8.0
1600 10.0
1700 10.0
1800 10.0
1900 12.00
2000 12.00
6
Nominal Internal Diameter Minimum wall thickness of joint rings.
(mm ) (mm )
2100 12.00
2200 12.00
2300 14.00
2400 14.00
2500 14.00
6.2.6 The pipe shall be free from local depressions or bulges greater than 5mm
extending over a length, in any direction.
The pipe shall be subjected to hydrostatic test after coating in accordance with
IS 3597. For this test, the pipe is placed on a hydrostatic test bench, filled with
water and pressure has to be raised slowly up to designed factory test pressure.
Pressure shall be maintained by pumping water as per IS 3597.The pipe must
not show leakage Damp or wet patches shall be accepted. If the pipe fails to
pass the test, it can be cured or repaired to improve its water tightness and then
retested. In case the pipe does not stand the rated internal pressure, it shall be
accepted for lower pressure to which it withstands, at the discretion of
Engineer-in-charge, provided all other requirements are conforming to this
standard.

exceed 0.3 cm3. When a higher result is obtained, the test shall be repeated on
twice the number of pipes originally tested and the lot shall be accepted, if all
pipes pass the test. Where retest is not satisfactory, all pipes from that lot may
be tested individually and only those with satisfactory results shall be accepted.
No additional treatment of any type shall be allowed on the pipe before
permeability test is taken. The test shall be done immediately after the
hydrostatic factory test. In case this is done later, then the pipe has to be kept
7
pipe shall be checked for delamination and hollows by tapping the exterior with
hammer having head of mass of not more than 0.5 kg. Any hollows or
drumming areas detected by sounding shall be repaired by approved method.


2. Pressure rating.
3. Nominal diameter
inscribed.

 The vehicle shall have side supports approximately spaced 2m apart, and the pipes
sharp edges.

such a way that they are secure and that no movement can take place on the vehicle
during transit. The same care is needed if pipes are to be transferred from one
vehicle to another, however, short the journey may be.
8
circumference of the pipe and should not be threaded through the pipe bore' as the
latter method may damage the jointing surfaces. For the same reasons, hooks

Following precaution shall be taken while stacking of pipes so as to eliminate potential
damages to pipes.
 Pipes may be placed directly on the ground provided it is reasonably level and free
from rocks and other projections.
succeeding tiers.
required.
10.0 Valves
10.1 Air Valve :
certain velocity, the air valve can discharge the remained gas in the pipe; secondly,
at the normal working stage, the air valve can discharge the small amount of gas
gathered in the pipe timely; finally, during the pump failure or maintenance stages,
9
the air valve will replenish the gas into the pipe to break the vacuum. According
to the orifice size, displacement and work pressure, air valve is divided into high
pressure trace exhaust valve, low pressure air release valve and combined air valve.
10.2 Scour Valve :
of Scour valves is frequently influenced by opportunities to dispose off the
water. Where the main pipeline crosses a stream or drainage structures, there
will usually be a low point in the line but if the main pipeline goes under the
stream or drain, it cannot be completely drained into the channel. In such a
situation it is better to locate a scour connection at the lowest point that will
drain by gravity and provide for pumping out the part below the drain pipeline.
control

A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve

10
12.2 Demarcation
marking out slopes, and labour required for line out should be provided by the
established by the Engineer In-charge in vicinity of PDN work will serve
as control points for these works. The Contractor shall establish
sufficient number of reference benchmarks for facilitating setting out of
work and taking levels for the purpose of measurements.
(b) Before starting any work, the Contractor shall erect reference
benchmarks, reference lines and check profiles at convenient locations
approved by the Engineer In-Charge. The benchmark concrete block
shall be 200mm x200mm x600mm with 400mm embedded in the firm
ground and 200 mm projecting above ground. The word ‘BM’ showing
value of R.L. in ‘m’ shall be conspicuously carved and painted on the
benchmark.
elevations to the profile or profiles indicated in the approved drawings.
All important levels and all control points with respect to benchmarks
and reference lines shall be fixed and correlated by the Contractor. The
Contractor is fully responsible for maintaining all setting out work &
Benchmark established by Engineer-In-charge.
(d) All materials, labour and equipments (theodolites, levels, distometre,
etc.) for setting out works including construction of benchmarks in
concrete, reference lines, check profiles and surveys as may be required
at the various stages of construction shall be supplied by the Contractor
at his cost. For this following numbers of minimum equipments shall
be provided and maintained in good working condition by the
Contractor.
11
3. Levels 2 Nos.
4. Staves 4 Nos.

the materials to be excavated and the difficulties of making and maintaining the
required excavation. The trench width at bottom shall be 300 mm more than
1.5 times outside pipe diameter. In any case trench width shall not be less than
500 mm.
channel from trench. When the drain/nalla bed is higher than the sub-soil water
level met with, the bailing out by suitable means of pumping shall be resorted
to for dewatering sub-soil water below the drain/nalla bed level. No distinction
shall be made as to whether the material being excavated is dry, moist, wet or
slushy. The Contractor shall have to excavate the PDN pipe trench and structure
in under water level conditions also i.e. under wet/slushy condition after
providing sufficient arrangement of dewatering. The material excavated under
water level condition which requires intermediate stacking for drying shall have
to be rehandled. No extra payment for efforts for drying out of soil, re-handling
of dry soil, etc. shall be given. No payment for extra efforts for excavation under
this condition shall be made.
12
for additional excavation as may be directed by the Engineer-In-charge, shall be
rectified at the cost of the Contractor. Filling and compaction for such over
excavation using the material as directed by the Engineer In- Charge shall also
be at the cost of the Contractor.
Engineer In Charge and such over excavated section shall be filled with

separately under relevant items. Above provision for over excavating and filling
with suitable murum type or good soil available material shall be applicable in
case such treatment is found essential.

While laying of PCCP pipe, all precaution as mentioned in IS 783 shall be taken.
Concrete pipes have to be properly handled, bedded & back filled, if they have to carry
the full design loads safely.
 Pipes should be lowered into the trench with tackle suitable for the weight of pipes,
such as well designed shear slings with chain block or mobile crane.
 While lifting, the position of the sling should be checked when the pipe is just clear
off the ground to ensure proper balance.
 When laying is not in progress, the open end of the pipe line should be fitted with
temporary end-closure. This may make the pipe buoyant in the event of the trench
becoming flooded and any movement of the pipes should be prevented either by
partial refilling of the trench or by temporary strutting.
• Expansion joints shall be provided for buried lines at maximum interval of 100m, if
rigid joints are used.
• Each pipe shall be thoroughly checked for any damages before laying and only the
pipes which are approved by the Engineer shall be laid.
• Bedding requirements are minimal due to rigid nature of pipe. However, while
laying in rocky area, 150 mm compacted fine sand bedding under and around pipe
needs to be provided.
13
shall be as little unevenness as possible along the inside of the pipe. As soon as
joint assembly is complete, the last pipe laid should be firmly restrained in
15.2 Jointing process of PCCP pipe consist of following steps.
 Aligning of pipes at joint locations.
 Field welding of socket ring at joint externally.
 Fixing of diaper with steel strap at joint location.
 Pouring of cement mortar through diaper at joint location.
 Filling inside of joints by cement mortar.
15.3 The basic requirements for all joints are as enumerated below.
a) cleanliness of all parts, particularly joint surface;
b) correct location of components;
c) centralization of spigot within socket;
d) provision of the correct gap between the end of the spigot and the back
of the socket
16.1 All pipelines should be tested before being brought into service. The test should
be a hydrostatic test performed by filling the pipeline with water and raising the
pressure to the selected test pressure and maintaining this for a sufficient period
to allow for absorption of water by the pipe material.
16.2 AS per I.S.784, the test pressure should be 1.5 times design working pressure.
16.3 Test procedure: Each section should be properly sealed off, preferably with
special stop secured by adequate anchors. The thrust on the stop ends should be
calculated on the full socket internal diameter and the anchors designed to resist
it. It may often be economical to provide .a concrete anchor block of couple of
pipes laid and earth tamped around which has subsequently to be demolished
rather than risk movement of the stop ends during testing. Hydraulic jacks may be
inserted between the temporary anchors and stop ends in order to take up any
horizontal movement of the temporary anchor. All permanent anchors should be
in position and, if of concrete, should have developed adequate strength before
testing begins. The section under test should be filled with water, taking care that
all air is displaced either through vents at the high points, or by using a swab.
After filling, the pipeline should be left under operating pressure for a
period in order to achieve conditions as stable as possible for testing. The length
of this period will depend upon many factors such as initial permeability,
absorption, movement of the pipeline under pressure and the quantity of air
trapped.
14
millimeter of pipe diameter per kilometer of pipeline per day for each 30 meter
head-of pressure applied.
16.4 Leak Detection - If the test is not satisfactory, the fault should be found and
rectified. Where there is difficulty in locating a fault, the section under test should
be subdivided and each part tested separately.
If any leakage is found during testing of pipeline, Contractor will have to attend the
same immediately and rectify at his cost within. If Contractor fails to rectify the
defect, the entire length of pipeline between two adjacent outlets shall be
rejected. If any intermediate payment is made to the Contractor for portion under
rejection, the same shall be recovered from the outstanding dues of the
Contractor.
pipeline, care being taken to ensure that the pressure at the lowest point in the
pipeline does not exceed the maximum. During the test, an inspection should be
made of all work which has not been subjected to sectional tests.

more than 15cm thickness, with the first layer watered and compacted by
the pipe. If sufficient quantity of suitable (Sharp edge stone free) excavated earth
is not available, the trench shall be filled by borrowed gravel material upto 300
mm above top of pipeline. Remaining trench can be filled with available material.
assumed in design of structure. The backfill close to the structure up to the rolled
layer shall be compacted in suitable uniform layers, using pneumatic / hand
tampers as appropriate for dry density at average bulk density (+/- 10%). The
moisture content of the earth fill placed against the rock or the structure shall
be on higher/lower side of OMC by about 2% or so, to allow it to be compacted.
15
Profuse watering shall be done to pervious materials (sand) before compaction
as per instruction of the Engineer-in-Charge. Compaction at junction of
earthwork and backfill around the structure shall be carried out with special care.

of this block shall be buried in ground projecting only 15cm above the ground

16
3 S.G.S, Mumbai
5 VJTI, Mumbai

periodical intervals at which such testing is to be done etc. shall be as per
the latest editions of relevant IS Codes and determined by the Engineer In-
mixes and placed concrete, mortar etc. shall be specified by the Engineer
In-charge from time to time and the Contractor shall provide free of cost all
control authorities for test shall be provided free of cost by the contractor.
Contractor.
17
Engineer in charge.

2 Laboratory Assistants(Twevlth Pass with Science
Two to Four
subject with 2 year experience in testing of
(As per work)
material)
(One for each L.A.)
by the contractor.

sand, coarse aggregates etc. shall be carried out in field laboratory set up
by the contractor in presence of quality control representative at contractors
18
contractor.

his own cost. The testing shall preferably be conducted jointly with members of
WUA/representative of Engineer In-charge, technical representative of
21.3 On completion of every Irrigation season, the contractor shall flush the pipe line
from its tail flush valve so that any siltation, vegetation or obstruction is cleaned
and pipe is able to flow designed discharge for next season.
19
from any damages.
Geotagged map of laid pipeline shall also be handed over to WUA.
21.6 In association of the members of WUA, the Engineer In-charge shall confirm the
release of designed discharge through every outlet before handing over. In case
of any short fall or defect, it should be made good from the contractor at his
own cost.

22.1 Measurement
22.2 Payment
The break up to payment for supplying, laying, jointing & hydrostatic testing
of pipeline shall be as under:-
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20
Specifications for
Bar/Wire Wrapped Steel
Cylinder Pipes (BWSC).
2020
0
Bar/Wire Wrapped Steel Cylinder (BWSC) Pipes.
1.0 Introduction :
Bar/Wire wrapped steel cylinder (BWSC) pipe comprises of a welded steel sheet
cylinder with steel socket & spigot rings welded to its ends, lined with centrifugally
applied cement mortar within the steel cylinder. Reinforcement consisting of
continuous steel bars/wire helically wound around the outside of the cylinder is
subsequently coated with dense cement mortar.
The Contractor shall provide on-site training on BWSC pipe laying, jointing, testing
and maintenance etc., to the personnel authorized by the Engineer-in-charge. The
contractor should provide technical manual on BWSC Pipes including precautions to

The manufacturing, testing, supplying, jointing, welding and testing at work site of
BWSC pipes shall comply with all currently applicable statutes, regulations,
standards, and Codes. In particular, the following standards, unless otherwise
specified herein, shall be referred. In all cases, the latest revision of the Codes shall
be referred to. If requirements of this specification conflict with the requirements of
the standards/ Codes, this specification shall govern. Other codes not specifically
mentioned here but pertaining to the use of BWSC pipes form part of these
specifications.
1
IS: Specifications for Bar/Wire Wrapped Steel Cylinder pipes
15155
IS: 7322 Specifications for Specials for Steel Cylinder Reinforced Concrete pipes
IS 383 Specifications for coarse & fine aggregates from natural sources for
concrete
IS 432 Specifications for Mild steel & medium steel bar/wire for Concrete
Part Concrete.
1&2
3.0 Raw Materials
Raw materials used to manufacture BWSC Pipes are cement, aggregates, water,
admixture, steel reinforcement, Steel plates. .
3.1 Cement
The cement used in the manufacture of BWSC pipes shall conform to one of
the following.
1) 43/53 grade Ordinary Portland Cement conforming to IS:8112/IS
12269
3) Portland Slag cement (with not more than 50% slag) conforming to
IS: 455
4) Sulphate Resisting Portland Cement conforming to IS: 12330
2
3.2 Aggregate
whichever is smaller. Silt Content in fine aggregates shall be less than 3
percent. The fineness modulus of aggregates for coating shall be between 2.6
to 3.2.
3.3 Water
other substances and shall conform to the requirements of mixing water as
per IS : 456.
3.4 Admixtures
3.5 Steel Reinforcement.

The reinforcement steel Bar/wire used for manufacturing BWSC Pipes shall
conform to IS: 432.
3.6 Steel plates for Cylinder, Joint Rings and Specials.

Steel plates for Cylinder, Joint Rings and Specials shall conform to IS:2062.
The manufacturing of pipes & specials for BWSC pipes shall be as per IS 15155.
Various steps involved in pipe manufacturing process are as given below.

• Fabrication and hydrostatic testing of steel cylinder as per required size.
• Welding of steel socket & spigot rings to end of steel cylinder.
• Placing of rich cement mortar lining in the core by centrifugal method. ( minimum
cement content- 540kg/m3 , minimum water cement ratio – 0.42, minimum
compressive strength of cement mortar at 28 days-35 N/mm 2, minimum
compressive strength of cement mortar at the time of wrapping of bar/wire -10
N/mm2)
• Spiral widening of circumferential reinforcing bar/wire around the cylinder.
3
• Rich cement mortar out coating ( Cover coating) on pipe (shall preferably be
applied within 16 hours after the bar/wire is wound). ( minimum cement content-
540kg/m3 , minimum water cement ratio – 0.27, minimum compressive strength
of cement mortar at 28 days-35 N/mm2).
• Curing of concrete.
Cross-section of BWSC Pipe Joint

BWSC pipe shall be designed to withstand the combined effects of internal water
pressure & external loads. Design of BWSC pipes shall be site specific as internal
water pressure will depend on pipe profile whereas external loads will depend on
maximum cover (i.e. overburden) over the crown of pipe.

requirements of IS 15155. Scale of sampling shall be as given following Table No.1
4
No Hydrostatic Coating Hydrostatic Diamensi Permeab

of testing of thickness test of pipe onal test ility test
pip Joint rings cylinder at factory (1)
es dimensions
in
lot
** ** ** ** * *
* * * * * *
* *
Upt Al All 3 1 3 3 N
NI N
o l NIL NIL NIL I
L IL
50 L
51- Al All 5 1 5 5 N
NI N
100 l NIL NIL NIL I
L IL
L
101 Al All 8 2 8 8 N
NI N
- l NIL NIL NIL I
L IL
300 L
300 Al All 13 2 13 13 N
NI N
- l NIL NIL NIL I
L IL
500 L
500 Al Nil All Nil 26 1 4 Nil 26 1 26 1
- l
100
0
(1)Includes socket and spigot
* Number of samples
** Number of defective samples
6.0 Pre-Delivery Testing Of Pipes

1) Steel cylinder test

5) Mortor soundness test
6.1 Steel Cylinder Test : During manufacturing, each steel cylinder with steel and
spigot rings welded on shall be subjected to water pressure which stresses the steel
to at least 140 N/mm2but not more than 175 N/mm2. While under stress, the
assembly, especially welds shall not show any leakage. If any leakage is found,
assembly shall be repaired and whole assembly retested.
5
6.2 Dimensions
6.2.1 Length -
Length of Pipe shall be 4m to 8m.
6.2.2 Nominal internal diameter of the pipes, minimum wall thickness and
minimum thickness of cement mortar lining shall be as per following
Table no.2
Table 2 Nominal Internal Diameter, Minimum wall thickness and Minimum

thickness of cement mortar lining
Nominal Minimum Minimum Minimum Minimum
Internal wall Thickness steel cylinder Thickness
Diameter of thickness of cement thickness of joint
Pipe (mm ) mortar (mm ) rings
(mm ) lining (mm )
(mm )
250 40 15 1.6 5.0
300 40 15 1.6 5.0
400 40 15 1.6 5.0
500 45 20 1.6 5.0
600 45 20 2.0 5.0
700 45 20 2.0 5.0
800 45 20 2.0 5.0
900 45 20 2.5 5.0
1000 45 20 2.5 7.0
1100 50 22 4.0 7.0
1200 50 22 4.0 7.0
1300 50 22 4.0 8.0
1400 50 22 4.0 8.0
1500 50 22 4.0 8.0
1600 50 22 4.0 8.0

6
6.2.4 The pipe shall be free from local depressions or bulges greater than
5mm extending over a length, in any direction.

The finished pipe shall be subjected to factory pressure test. The pipe
shall be tested in accordance with IS 3597.One in 50 pipes shall be subjected
to an internal hydrostatic test. Should a pipe fail the test, then a further two
pipes from the same batch of 50 shall be tested. If both pipes pass, then the
batch shall be accepted. If one or both pipes fail then the batch shall be
rejected or each pipe in the batch shall be tested for individual approval. The
pipe shall be tested for a period of 3 min. During the test the pipe shall be
absolutely water-tight and show no leaks, weeping or defects considered
detrimental to the pipe’s performance. No crack in the external surface shall
be wider than 0.5 mm on a length exceeding 300 mm using a feeler gauge.

exceed 0.3 cm3. When a higher result is obtained, the test shall be repeated
on twice the number of pipes originally tested and the lot shall be accepted, if
all pipes pass the test. Where retest is not satisfactory, all pipes from that lot
may be tested individually and only those with satisfactory results shall be
accepted. No additional treatment of any type shall be allowed on the pipe
before permeability test is taken. The test shall be done immediately after the
hydraulic factory test. In case this is done later, then the pipe has to be kept
pipe shall be checked for delamination and hollows by tapping the exterior
with hammer having head of mass of not more than 0.5 kg. Any hollows or
drumming areas detected by sounding shall be repaired by approved
method.

Each pipe shall be indelibly marked in English language at either end of each pipe.
The marking shall show the following.
2. Pressure rating.
3. Nominal diameter
7
inscribed.
 The vehicle shall have side supports approximately spaced 2 m apart, and the
pipes shall be secured effectively during the transportation. All posts shall be flat
with no sharp edges.

 Pipes should be loaded at the works for transportation, either by rail or by road,
in such a way that they are secure and that no movement can take place on the
vehicle during transit. The same care is needed if pipes are to be transferred from
one vehicle to another, however, short the journey may be.
circumference of the pipe and should not be threaded through the pipe bore' as
the latter method may damage the jointing surfaces. For the same reasons, hooks
8

Following precaution shall be taken while stacking of pipes so as to eliminate
potential damages to pipes.
 Pipes may be placed directly on the ground provided it is reasonably level and
free from rocks and other projections.
succeeding tiers.
required.
10.0 Valves
10.1 Air Valve :

9
10.2 Scour Valve :

A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve


The Contractor shall clear the entire area required for setting out. All
tree stumps, roots, brushwood, rubbish of all kinds, loose stones and all other
10
12.2 Demarcation
marking out slopes, and labour required for line out should be provided by
the Contractor at his own cost. The center line of excavation shall be clearly
established by the Engineer In-charge in vicinity of PDN work will serve
as control points for these works. The Contractor shall establish sufficient
approved by the Engineer In-Charge. The benchmark concrete block shall
be 200mm x200mm x600mm with 400mm embedded in the firm ground
and 200 mm projecting above ground. The word ‘BM’ showing value of
R.L. in ‘m’ shall be conspicuously carved and painted on the benchmark.
elevations to the profile or profiles indicated in the approved drawings.
All important levels and all control points with respect to benchmarks and
reference lines shall be fixed and correlated by the Contractor. The
(d) All materials, labour and equipments (theodolites, levels, distometre,
etc.) for setting out works including construction of benchmarks in
concrete, reference lines, check profiles and surveys as may be required
at the various stages of construction shall be supplied by the Contractor
at his cost. For this following numbers of minimum equipments shall
be provided and maintained in good working condition by the
Contractor.
11
3. Levels 2 Nos.
4. Staves 4 Nos.
All equipments shall be of standard and approved make and precision,

and shall be made available in advance of starting of the work. All
equipment shall be maintained, repaired and got tested and certified
as and when required for its accuracy from the standard test houses or
from the manufactures and to the satisfaction of the Engineer-In-
Charge.

than 500 mm.
12

While laying of BWSC pipe, all precaution as mentioned in IS 783 shall be taken.
Concrete pipes have to be properly handled, bedded & back filled, if they have to
carry the full design loads safely.
 Pipes should be lowered into the trench with tackle suitable for the weight of
pipes, such as well designed shear slings with chain block or mobile crane.
 While lifting, the position of the sling should be checked when the pipe is just
clear off the ground to ensure proper balance.
 When laying is not in progress, the open end of the pipe line should be fitted with
temporary end-closure. This may make the pipe buoyant in the event of the
trench becoming flooded and any movement of the pipes should be prevented
either by partial refilling of the trench or by temporary strutting.
• Expansion joints shall be provided for buried lines at maximum interval of 100m,
if rigid joints are used.
• Each pipe shall be thoroughly checked for any damages before laying and only
the pipes which are approved by the Engineer shall be laid.
• Bedding requirements are minimal due to rigid nature of pipe. However, while
laying in rocky area, 150 mm compacted fine sand bedding under and around
pipe needs to be provided.

shall be as little unevenness as possible along the inside of the pipe. As soon
as joint assembly is complete, the last pipe laid should be firmly restrained in
13
15.2 Jointing process of BWSC pipe consist of following steps.
 Aligning of points at joint locations.
 Field welding of socket ring at joint externally.
 Fixingof diaper with steel strap at joint location.
 Pouring of cement mortar through diaper at joint location.
 Filling inside of joints by cement mortar.
15.3 The basic requirements for all joints are as enumerated below.
a) Cleanliness of all parts, particularly joint surface;
b) Correct location of components;
c) Centralization of spigot within socket;
d) Provision of the correct gap between the end of the spigot and the back of
the socket
16.1 All pipelines should be tested before being brought into service. The test
`16.2 AS per I.S.784 the test pressure should be 1.5 times design working pressure.
16.3 Test procedure : Each section should be properly sealed off, preferably with
special stop secured by adequate anchors. The thrust on the stop ends should
be calculated on the full socket internal diameter and the anchors designed to
resist it. It may often be economical to provide .a concrete anchor block of
couple of pipes laid and earth tamped around which has subsequently to be
demolished rather than risk movement of the stop ends during testing.
Hydraulic jacks may be inserted between the temporary anchors and stop ends
in order to take up any horizontal movement of the temporary anchor. All
permanent anchors should be in position and, if of concrete, should have
developed adequate strength before testing begins. The section under test
should be filled with water, taking care that all air is displaced either through
vents at the high points, or by using a swab. After filling, the pipeline should
be left under operating pressure for a period in order to achieve conditions as
stable as possible for testing. The length of this period will depend upon many
factors such as initial permeability, absorption, movement of the pipeline
under pressure and the quantity of air trapped.

14
millimeter of pipe diameter per kilometer of pipeline per day for each 30
meter head-of pressure applied.
16.4 Leak Detection - If the test is not satisfactory, the fault should be found and
rectified. Where there is difficulty in locating a fault, the section under test
should be subdivided and each part tested separately.
If any leakage is found during testing of pipeline, Contractor will have to
attend the same immediately and rectify at his cost within. If Contractor fails
to rectify the defect, the entire length of pipeline between two adjacent
Contractor for portion under rejection, the same shall be recovered from the
outstanding dues of the Contractor.
pipeline, care being taken to ensure that the pressure at the lowest point in
the pipeline does not exceed the maximum. During the test, an inspection
should be made of all work which has not been subjected to sectional tests.

earth is not available, the trench shall be filled by borrowed gravel material upto
300 mm above top of pipeline. Remaining trench can be filled with available
material.
15
special care.


Third party Inspection can be done form any one of the following services or
from any other mutually agreed agency.
16
3 S.G.S, Mumbai
5 VJTI, Mumbai
per the latest editions of relevant IS Codes and determined by the Engineer
In-charge. The day-to-day and periodical tests to be carried out on
materials mixes and placed concrete, mortar etc. shall be specified by the
Engineer In-charge from time to time and the Contractor shall provide free
of cost all facilities towards collections of samples etc. unless otherwise
specified. Labours for collecting samples and transportation of the samples
to quality control authorities for test shall be provided free of cost by the
contractor. Also electricity, fuel, water curing tank and stores etc shall be
provided free of cost by the contractors.
Contractor.
17
Engineer in charge.
Sr.
No.
2 Laboratory Assistants(Twevlth Pass with Science Two to Four
subject with 2 year experience in testing of material) (As per work)
(One for each
L.A.)

Sr.
No.
by the contractor in presence of quality control representative at
contractors cost. Contractor shall through this procedure assure the quality
of work.
18
collecting samples or testing, the results will be considered as authentic
and binding on the contractor.
contractor.
from any damages.
19
at his own cost.

22.1 Measurement
22.2 Payment
The break up to payment for supplying, laying, jointing & hydrostatic testing
of pipeline shall be as under:-
----------***---------
20
SPECIFICATIONS FOR
MILD STEEL PIPES (M.S.)
2020
0
SPECIFICATION FOR MILD STEEL PIPES (M.S)
1.0 Introduction
Mild steel Pipes can be manufactured from mild steel produced by the open hearth
or electric furnace or one of the basic oxygen processes. The pipes shall be
manufactured by either seamless(s) process or electric resistance inducing induction
welding (ERW) process or Submerged Arc Welding (SAW) process.
The Contractor shall provide on-site training on M.S. pipe laying, jointing,
testing and maintenance etc., to the personnel authorized by the Engineer-in-charge.
The contractor should provide technical Manual on M.S. pipes including precautions
to be taken during operation of the pipeline.

of M.S. pipes shall comply with all currently applicable statutes, regulations,
specified herein, shall be referred. In all cases the latest revision of the Codes shall be
referred to. If requirements of this Specification conflict with the requirements of the
standards/Codes, this Specification shall govern. Othpers Codes not specifically
mentioned here but pertaining to the use of M.S. Pipes form part of these
Specifications.
IS: 3589 Specification for Steel pipes for Water and Sewage (168.3 to 2540
mm Outside Diameter).
Note: The provisions of various clauses of the above IS code are
deemed to be applicable to diameters above 2540mm as well.
IS: 5822 Code of Practice for Laying of Electrically Welded steel pipes for
water supply.
Note: The provisions of various clauses of the above IS code are
deemed to be applicable to diameters above 2540mm as well.
I.S.4711 Methods for sampling of steel pipes, tubes & fittings
IS: 2062 Specification for Hot Rolled Medium and High Tensile Structural Steel
IS: 814 Specification for Covered Electrodes for Manual Metal Arc Welding
of Carbon and carbon Manganese Steel
IS: 3613 Acceptance tests for wire flux combinations for submerged arc
welding.
IS: 456 Code for practice for plain and reinforced concrete.
IS: 800 Code of practice for general construction in Steel.
1
IS: 816 Code of practice for use of Metal Arc Welding for General
Construction in mild steel
IS: 4353 Recommendation for Submerged Arc Welding of Mild Steel & Low
Alloy Steels.
IS: 1182 Recommended practice for Radiographic examination of Fusion-
Welded Butt Joints in steel plants.
IS: 2595 Code of Practice for Industrial Radio-graphic Testing.
IS: 4853 Recommended Practice for Radiographic Examination of Fusion
Welded Butt Joints In Steel Pipes.
3.0 Raw Materials
Raw material use to manufacture the M.S. Pipes (with or with or coating) is steel
plates, Welding Consumables, Cement, aggregate, water, admixtures, steel
reinforcement, primer, red oxide paint.
3.1 Steel Plates - The steel plates for pipes, fittings, specials shall be of mild steel
of various grades conforming to IS 2062. Steel plates shall be procured from reputed
manufacturers such as JINDAL, SAIL, ESSAR, ISPAT TISCO etc.
3.2 Welding Consumables : Welding consumbales such as electrodes, filler rods

and wires shall conform to IS 814, IS 3613, IS 6419 and IS 7280.
3.3 Cement : The cement used for coating to in the manufacture of M.S.pipes shall
confirm to one of the following.
1) 43/53 grade Ordinary Portland Cement confirming to IS:8112/IS 12269
2) Rapid Hardening Portland cement confirming to IS: 8041
3) Slag cement (with not more than 50% slag) confirming to IS: 455
4) Sulphate Resistant Cement confirming to IS: 12330
3.4 Aggregate : The coarse and fine aggregates shall conform to I.S.383. The
maximum size of aggregate shall not exceed one third the thickness of the pipe or
20mm whichever is smaller. Silt Content in fine aggregates shall be less than 3
percent. The fineness modulus of aggregates for coating shall be between 2.6 to 3.2.
3.5 Water : The water used in the preparation of concrete mix shall be clean and free
from harmful or injurious compounds such as acids, alkali, oil, organic material or
other substances and shall conform to the requirements of mixing water as per IS :
456.
3.6 Admixtures : Admixtures may be used with the approval of the purchaser.
However, use of any admixture containing chlorides in any form shall be prohibited
The admixtures shall conform to IS 9103.
2
3.7 Steel for Reinforcement : Steel reinforcement shall conform to IS
1786:2008
3.8 Primer : The primer shall be of Zinc Rich Epoxy type.

Manufacturing of pipes can be carried out either by seamless process(s) or Electric
resistance including induction weldinbg process (ERW) or submerged are welding
rocess(SAW). The General manufacturing process of M.S. Pipe is as given the below.
 Cutting plates to required sizes.
 Rolling of plates to form a pipe of required diameter.
 Tacking of drums.
 Assembly of drums into pipes.
 Shop welding.
 Radiographic testing of welded joints.
4.1 Radiography of Welded Joints

As soon as practicable, after Shop welding is done, minimum 15% (fifteen percent)
length of the weld at random for each pipe shall be radiographed, to detect welding
defects. This 15% sampling will be at random to ensure 100% coverage of junctions
of longitudinal and circumferential joints. If the results of such radiography fail to
conform to the requirements, the Contractor shall carry out as directed additional or
100 percent radiography test for the pipe at the Contractor's cost to the satisfaction
of Engineer.
For specials like bends, tapers, tees and Wyes radiography test shall be conducted for
100 percent length of welds.
Designation
The pipes shall be designated by the method of manufacture followed by the grade
number corresponding to the minimum specified tensile strength in MPs following
the symbol Fe as given in Table 1
Example:
ERW- Fe 410 indicates electric resistance welded or induction welded steel pipe
having a minimum tensile strength of 410 MPa.
3
Table 1 Designation of the Grades of the pipes
Method of manufacture of Pipe Reference Steel Grades Applicable

(1) (2) (3) (4) (5)
Seamless S Fe 330 Fe 410 Fe
450
Electric resistance including ERW Fe 330 Fe 410 Fe
induction welded 450
Submerged arc SAW Fe 330 Fe 410 Fe
welded(including spirally 450
welded )
Note – Method of manufacture of pipe and steel grades other than specified above shall be as agreed
to between the manufacturer & the purchaser.
The size of the pipes shall be designated by their outside diameters in mm.
4.3 Protective coating for pipes : Generally pipes are coated internally as well as
externally for corrosion protection as per provisions of IS 3589. Various types of
coatings applied to MS pipes are as mentioned below.
4.3.1 Cement Mortar Lining : The inside of all pipes shall receive a cement mortar
lining applied by centrifugal spinning, whereas outside of pipe shall receive a
reinforced cement mortar coating ( i.e. Gunniting with wire mesh) applied by either
mechanical or pneumatic placement. The minimum thickness of inside mortar lining
shall be 6 to 12mm depending on outside diameter of pipe as given in IS 3589,
whereas minimum thickness of outside cement mortar coating (i.e. Gunnitting) shall
be 20mm.
4.3.2 Liquid Epoxy Coating : This system may consists of any one of the following three
types.
(i) two part chemically cured epoxy primer and one or more coatings of a different
two-part, chemically cured Epoxy top coat.
(ii) two or more coats of the same two-part, chemically cured epoxy coating, in which
case the first coat shall be considered as the primer coat.
(iii) a single coat of two-part, solvent for chemically cured epoxy coating.
 Unless otherwise specified by the purchaser, the minimum dry film thickness
DFT provided shall be atleast 406 micronm .
 After curing but prior to burial the coating system shall be a continous film,
free of thin spots and other imperfections and shall pass electrical inspection
for continuity.

4
4.3.3 Fusion bonded epoxy coating :
MATERIAL
The epoxy powder shall consist of a one-component, fusion bonded material
consisting of epoxy resin, curing agents, catalysts, fillers, colorants, flow control
agents, and ultraviolet light resistant agents that when applied to the preheated
substrate, will uniformly coalesce and cure to produce a homogeneous film that
complies with the requirements of this standard.
Application capability, when applied by electrostatic spray, fluidized bed, or air spray
to the preheated article and subsequently cured, the epoxy powder shall produce a
uniform protective coating.
PIPE COATING APPLICATION

When both an internal and an external coating are to be applied, it is preferable to
preheat the pipe to the specified temperature and apply the internal coating first,
immediately followed by the external coating, since elevated temperatures are
required during processing, fusion bonded epoxy coating must be applied prior to the
application of other coatings or linings unless those coatings and linings are resistant
to the processing heat.
4.3.4 Tape coating system:

For corrosion protection of metal pipes often several outer wraps, hot or cold applied
are used. For very corrosive soil condition cold applied tapes are used on steel pipes
at site. In the factory normally hot applied tape coating are used. Unless the
transportation is made very carefully these factory applied tape coating may get
damaged.
For normal construction considerations cold applied tapes are applied as a three layer
system consisting :
a) primer
b) Corrosive preventive tapes (inner layer)
c) Mechanical protective tape (outer layer)
The primer shall be applied to the properly prepated pipe surface before application
of the inner layer tape.
The inner layer tape shall consist of a polyolefin backing with a laminated adhesive.
The inner layer tape shall be applied after the primer and before the outer layer tape.
The outer layer shall consist of polylefin backing with a laminated elastomer type
adhesive.
5
All pipes manufactured by the same process under similar conditions of production
shall constitute a lot.
The number of pipes to be selected from a lot for the checking of dimensional
characteristics depends on the size of the lot and shall be taken in accordance with
relevant columns of following Table No.2. AII these items shall be taken at random
from the lot by using suitable random number tables or by using any other procedure
which ensures randomness.
Table No.2 Scale of Sampling and Permissible Number of Defectives for Mass and
Dimensional Characteristics
Each of the items selected according to above shall be inspected for dimensional
characteristics as mentioned below para 6.0. Any items failing to meet one or more
dimensional requirements shall be considered as defective. If the number of
defective found in the sample checked for dimensional characteristics is less than or
equal to the corresponding acceptance number, the lot shall be deemed as having
met the dimensional requirements of the relevant specification, otherwise not.In the
case of those lots which have been found unsatisfactory, all the items in the lot may
be inspected for dimensional characteristics and the defective be removed, if agreed
to between the purchaser and the supplier.
6
The lot shall also be tested for appropriate physical characteristics like tensile
strength, bend, flattening and drift tests. The number of items to be drawn in
accordance with following Table 3 may be taken at random from that already drawn
for dimensional inspection.
Table No.3 Scale of Sampling and Permissible Number of Defectives for Physical
tests (Tensile, Bend, Flattening and Drift)
For any of the physical tests, if in the first sample the number of defective items is
less than or equal to the corresponding acceptance number (a) the lot shall be
declared as conforming to the requirement of that test. If the number of defective is
greater than or equal to the corresponding rejection number (r), the lot shall be
deemed as not meeting the requirement of that particular physical test. If the
number of defective is greater than the acceptance number but less than the
rejection number, a second sample of the same size as the first shall be taken to
determine the conformity or otherwise of the lot. The number of defective found in
the first and second samples shall be combined and if the combined number of
defective is less than or equal to the corresponding acceptance number of the second
sample, the lot shall be declared as conforming to the requirements of the particular
physical test, otherwise not. Each pipe shall be hydraulically tested at the
manufacturer’s works before the pipe is coated, wrapped or lined.
7
1) Diamensions- outside diameter wall thickness, ovality, straightness.

2) Tensile strength
3) Flattening test
4) Guided bend test
5) Hydraulic pressure test
6.1 Dimensions :
6.1.1 Outside diameter : The tolerance on the specified outside diameter of pipe wall
shall be as given in following Table No.4
Tolerance on outside diameter of pipes.
Outside diameter (for all sizes ) Tolerance

1 2
For seamless pipes ±1%
For ERW & SAW pipes ±0.75%
6.1.2 Wall thickness : the tolerance on the specified wall thickness of pipe shall be as
follows.
ERW pipe : ±10%

SAW and seamless pipe +20%
-12.5%
6.1.3 Ovality : Ovelity shall not exceed 1% of the specified outside diameter for pipes
having diameter to thickness ratio not exceeding 100. Where the diameterto
thickness ratio exceeds 100 the tolerance on ovality is not specified and should be
agreed between the manufacturer & the purchaser.
6.1.4 Straightness : Finished pipe shall not deviate from straightness by more than
0.2 % of the total length.
6.2 Tensile Strength : The tensile properties of strip cut longitudinally (excluding the
weld) from selected pipes shall show the properties as given in following Table No.5.
8
Steel Method Em Es A
grades Tensile Yield Elongation %
Strength MPa Stress GI5.65
Min Min Min
Fe330 ERW & seamless & 330 195 20
SAW
Fe410 ERW & seamless & 410 235 18
SAW
ERW & seamless & 450 275 15
SAW
Yield stress valus are for design purposes only either the upper yield stress ReH or the 0.5 % of proof stress
(total elongation) ReH 0.5 is to be determined.
6.3 Flattening test ( for ERW or seamless pipes).

(i) Flattenig test for ERW pipe.
The test shall be made on ring sample not less than 40mm in length cut from the ends
of the selected tubes which shall be flattened between parallel plates keeping the
weld at 90 degree to the direction of the force. No opeing shall occur by fracture in
the weld until the distance between the plates is less than 75% of the original outside
diameter of the pipe and no crack or breaks on the metal elsewhere than in the weld
shall occur until the distance between th plates is less than 60% of the original;
outside diameter.
(ii) Flattening test for seamless pipes.
This test shall be carried out in accordance with IS 2328. A ring not less than 40mm
long cut from one end of each selected pipe shall when cold be flattened between
two parallel flat surfaces without showing either crack or flaw until the distance
between the plates H(mm) measured under load is not greater than the value given
by the following equation H=(1+c)a/c+a/d
Where a=specified thickness of the pipe (mm)
d=spefied outside diameter of the pipe(mm)
c=a constant dependent on the steel grade
Value of C=0.09 for Fe330
=0.07 for Fe410 & Fe450
Notes:
i. If any flaw appears during flattening test it may be removed by grading or filling. In
such case if the remaining wall thickness is not less than the minimum permitted
thickness as per clause the sample shall be accepted.
ii. superficial rupture resulting from surface imperfections shall not be cause of
rejection.
9
6.4 Guided bend test (for SAW pipes).
Strips not less than 40mm wide cut circumferentially from pipes perpendicular to
weld seam which the weld near the middle of the sample shall without fracture be
doubled over around bar the diameter of which shall be calculated as given below.
The weld reinforcement shall be removed from the faces.
The specimen shall not be fractured completely. Cracks 6.35 mm or less in length at
the edge of the specimen or 3.18mm or less in length in the centre of the specimen
shall be disregarded. Any crack greater than 3.18mm in length and regardless of the
depth located within the weld metal shall be a cause of rejection. Any pop-out greater
than 3.18mm in length (6.35mm at the edge)& 12.5% or less of the specified wall
thickness in depth and located in the parent metal. The heat affected zoze, or the
fusion line, shall not be the cause for rejection.
6.5 Hydraulic pressure test:

Each pipe shall be hydraulically tested at the manufacturer’s work before the pipe is
coated, wrapped & lined.
The hydraulic test pressure shall be the pressure calculated as [per the following
formulae
P =2ST/D
Where
P= hydraulic test pressure MPa
D=specified outside diameter of the pipe in mm’
T=specified thickness of the tube in mm
S= stress 60% of the specified minimum yield stress in MPa. The maximum tress
pressure to be limited to 5MPa wherever applicable.
The hydraulic test pressure shall be applied for 5s.
The test pressure shall ensure that the plate material is stressed to 80% of the
minimum yield strength and at least 1.5 times the allowable working pressure as
specified by the Engineer. Each pipe shall be filled with water and the pressure slowly
and uniformly increased until the required test pressure is reached.
The maximum elapsed Time shall Not Exceed the Maximum Time as given:- Maximum
4.0 Hrs.Any pipe showing flash rusting shall be relisted.
The blast cleaned pipe surface shall be tested for the presence of soluble salts. If the
concentration is more than 2µgm/cm², the pipe surface shall be chemically cleaned
using phosphoric acid or any other suitable method. The cleaned pipe shall be
retested to confirm the removal of soluble salts. Any foreign material or shot/grit
present in the pipe shall be removed by suitable means (mechanical brush, high-
pressure air jets, etc.) the Blast cleaned surface shall not be contaminated with dirt,
dust metal particles. Oil water or any other foreign material, nor shall the surface or
10
its anchor pattern be scarred or burnished. All blast cleaned pipe surface shall be
thoroughly inspected under adequate lighting to determine anchor pattern, quality
of blasting and identify any surface defects prior to coating application.


3. Outside diameter and wall thickness
be inscribed.
Following precaution shall be taken during transportation of pipe.
 The vehicle shall have side supports approximately spaced 2 m apart, and the pipes
sharp edges.
 Padding shall be provided between coated pipes and timber skids to avoid damage
to the coating.
 Pipes manufactured at factory are to be carried to the site of work directly or stacked
suitably and neatly along the alignment/ road side/elsewhere near by the work site,
as directed by the Engineer.
 All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded carefully
using crane/ tripod. No unloading using crow bars or on tires will be allowed in any
case. Rubber belt may be used instead of crow bars or chains.
such a way that they are secure and that no movement can take place on the vehicle
during transit. The same care is needed if pipes are to be transferred from one vehicle
to another, however, short the journey may be.
 The pipes and specials shall be handled in such a manner as not to distort their
circularity or cause any damage to their out coating
 Pipes shall not be thrown down from the trucks nor shall be dragged or rolled along
hard surfaces.
11
 Slings of canvas on equally non-abrasive material of suitable width or special
attachment shaped to fit the pipe ends shall be used to lift and lower coated pipes
so as to eliminate risk of damage to the coating.
9.0 Stacking of Pipe at Site

Following precaution shall be taken so as to eliminate potential damage to pipes.
• Pipes shall be stored such that they are not in contact with direct sunlight,
lubricating or hydraulic oils, petrol, solvents and other aggressive materials.
• Suitable gap in pipes stacked should be left at intervals to permit access from one
side to the other
• Pipes should not be subjected to rough handling during stacking operations.
Rollers shall be used to move, drag the pipes across any surface.
• Dragging pipes over rough ground should be avoided.
• Pipe shall be stacked on reasonable flat surface, free from sharp object, stone or
projection likely to deform or damage the pipes.
10.0 Valves
10.1 Air Valve :

10.2 Scour Valve :
12
A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve

13
12.2 Demarcation
Engineer-In-charge.
14
3. Levels 2 Nos.
4. Staves 4 Nos.
than 500 mm.
15

While laying of MS pipes, all precautions as mentioned in IS 5822 shall be taken.
 Before the pipe is lowered, the trench shall be carefully examined to
determine that even bedding is provided for the pipeline and that the pipe
may be lowered into it without damaging the coating. While laying in rocky
areas, 150 mm compacted fine sand bedding under and around pipe needs to
be provided.
the pipes which are approved by Engineer shall be laid.
 Where the coating is to be done in the trench, the pipe may be lowered in the
trench on supports sufficiently high so as to facilitate out-coating. The pipe
should be lowered progressively with the help of shear legs or cranes using
wide belts or slings.
 In case of coated pipes, extra care shall be taken to preserve the coating while
lowering. Slings may be removed progressively without the necessity of
digging under the pipe.
 After the pipe is lowered, it shall be laid in correct line and level by use of
levelling instruments, sight rails, theodolites, etc.
16
 Care shall be taken to see that the longitudinal joints of the consecutive pipes
are staggered by at least 30” and should be kept in upper third of the pipeline,
if there are two longitudinal joints they should be on the sides.
 While assembling, the pipe faces shall be brought close enough to leave a
uniform gap not exceeding 3 mm.
 The spiders from inside and tightening rings from outside or other suitable
equipment should be used to keep the two faces in shape and position till at
least one run of welding is carried out.
 The pipe faces shall first be tack-welded alternately at one or more
diametrically opposite pairs of points. After completing tack-welding, full
welding shall be carried out in suitable runs following a sequence of welding
portions of segments diametrically opposite.

Jointing of pipes by welding shall be done as per procedure mentioned in IS 3589
& IS 5822
 Before aligning, assembling and welding, the pipe faces shall be cleared by
scraping by wire brushes or any other method specified by the authority.
 The welding of pipes in the field should comply with IS 816
 Electrodes used for welding should comply with IS 814
 Joints are welded by butt welding using either plain ends or beveled ends.
Beveled ends shall be beveled to an angle of 30 0 (+ 50 -0 0) measured from a
line drown perpendicular to the axis of the pipe. The root face shall be 1.6±0.8
mm
17
 The welded joints shall be tested in accordance with procedure laid down in IS
3600 (Part 1) : 1985. One test specimen taken from at least one field joint out
of any 10 shall be subjected to test.
 If the results of the tensile test do not conform to the requirements specified,
retests of two additional specimen from the same section shall be made, each
of which shall conform to the required specifications. In case of failure of one
or two, extensive gouging (scooping out) and repairing shall be carried out as
directed by the authority.

16.1 General
 The field test pressure should not be less than the greatest of the following
a) 1 times the maximum sustained operating pressure
b) 1 times the maximum pipeline static pressure, and
c) Sum of maximum static pressure and surge pressure subjected to the test
pressure.
 Where the field test pressure is less than two – thirds the test pressure, the
period of test should be at least 24 hours.
 The pressure shall be gradually raised at the rate of nearly 0.1 N/mm2 per
minute.
16.3 Test Procedure
 Each valved section of the pipe shall be slowly filled with clear water and all
air shall be expelled from the pipeline through hydrants, air valves fixed on the
pipeline.
 Each valved section of pipe shall be filled with water slowly and the specified
test pressure, based on the elevation of lowest point of the linear section
under test and corrected to the elevation of the test gauge, shall be applied by
means of a pump connected to the pipe in a manner satisfactory to the
authority.
 If a drop in pressure occurs, the quantity of water added in order to re-
establish the test pressure should be carefully measured. This should not
exceed 0.1 lit per mm of pipe dia per km of pipeline per day for each 30 m
head of pressure applied.
18
16.4 Leak Detection
Examination Under Pressure.
Under the test pressure no leak or sweating shall be visible at all section
of pipes, fittings, valves, hydrants and welded joints. Any defective pipes,
fittings, valves or hydrants discovered in consequence of this pressure test
shall be removed and replaced by sound material and the test shall be
repeated until satisfactory to the Authority.
If the test is not satisfactory, the fault should be found and rectified.
Where there is difficulty in locating a fault, the section under test should be
subdivided and each part tested separately.
If any leakage is found during testing of pipeline, Contractor will have
to attend the same immediately and rectify at his cost. If Contractor fails to
rectify the defect, the entire length of pipeline between two adjacent outlets
shall be rejected. If any intermediate payment is made to the Contractor for
portion under rejection, the same shall be recovered from the outstanding
dues of the Contractor.

material, shall be subject to approval. As far as practicable, backfill material shall
be obtained from the excavation for structures or from adjacent PDN excavation.
more than 15cm thickness. With the first layer watered and compacted by
matters etc. shall be used first. If sufficient quantity of suitable (Sharp edge stone
free) excavated earth is not available, the trench shall be filled by borrowed
gravel material upto 300 mm above top of pipeline.
structures, Rollers shall not be used close to structures as structural damage is
assumed in design of structure. The backfill close to the structure up to the rolled
layer shall be compacted in suitable uniform layers, using pneumatic / hand
tampers as appropriate for dry density at average bulk density (+/- 10%). The
moisture content of the earth fill placed against the rock or the structure shall be
on higher/lower side of OMC by about 2% or so, to allow it to be compacted.
Profuse watering shall be done to pervious materials (sand) before compaction
as per instruction of the Engineer-in-Charge. Compaction at junction of
19
earthwork and backfill around the structure shall be carried out with special care
without claiming any extra cost.
(g) Backfilling should closely follow the welding of joins of the pipe so that the
protective coating of pipe should not be subsequently damaged.
(h) The spiders provided during assembly and welding shall be retained until the
trench is refilled and consolidated. Where timbers are placed under the pipeline
to aid alignment, these shall be removed before backfilling. For further
precautions and use of material in backfilling, reference should be made to IS
3114 : 1994.

20

3 S.G.S, Mumbai
5 VJTI, Mumbai
21
Contractor.
Engineer in charge.
22
Sr.
No.

generation work)
2 Laboratory Assistants(Twevlth Pass with Two to Four

testing of material) (As per work)
(One for each L.A.)
Sr.
No.

Sieves for Sand & Metal.
Field testing Equipments


by the contractor in presence of quality control representative at
contractors cost. Contractor shall through this procedure assure the quality
of work.
23
presence of Engineer-in-Charge or his representative /QC present on site.
The contractor or his authorized representative shall have a free access in
these laboratories, to get himself satisfied about procedures of testing etc.
Even if the contractor or his representative fails to remain present while
collecting samples or testing, the results will be considered as authentic
and binding on the contractor.
contractor.
24
from any damages.
at his own cost.
22.1 Measurement
22.2 Payment


25


26
SPECIFICATIONS FOR
DUCTILE IRON PIPES (DI)
2020
0
SPECIFICATION FOR DUCTILE IRON PIPES (DI)
1.0 Introduction
Ductile iron (DI) pipes are manufactured from ductile iron. Ductile iron is a type of
iron in which graphite is present primarily in spherical or nodular form.
The Contractor shall provide on-site training on DI pipe laying, jointing, testing and
maintenance etc., to the personnel authorized by the Engineer-in-charge. The
contractor should provide technical Manual on DI pipes including precautions to be
taken during operation of the pipeline.

The manufacturing, testing, supplying, laying, jointing and testing at work sites of DI
mentioned here but pertaining to the use of PSC Pipes form part of these
Specifications.
IS 8329 Centrifugally cast(spun) ductile iron pressure pipes for water, gas and
sewage
IS 9523 Ductile iron fittings for pressure pipes for water, gas and sewage
IS 12288 Code of practice for use and laying of Ductile Iron pipes
IS 11606 Methods for sampling of Cast Iron pipes and fittings
IS 5382 Rubber sealing rings for gas mains, water mains and sewers
IS 638 Specification for Sheet Rubber Jointing and Rubber Insertion Jointing
IS 1608 Mechanical testing of metals -tensile testing
IS 1500 Methods for Brunel hardness test for metallic materials
3.0 Raw Materials

Raw material used in manufacturing of pipes (with or without coating) is ductile iron,
cement, sand,water,zinc, bitumen, plyethylene and rubber gasket.
3.1 Ductile Iron :

The general requirements relating to the supply of DI metal used in pipe
manufacturing shall be as per IS 1387 and IS 8329. The metal used for the
1
manufacture of pipes shall be of good quality commensurate with the
mechanical requirements specified in IS8329.
3.2 Cement : The cement used for the pipe lining shall conform to the existing
standards of cement. Following types of cement can be used for lining.
a) Ordinary Portland cement conforming to IS 8112 or IS 415.
b) Sulphate resisting Portland cement conforming to IS 12330 or IS 6909.
c) High alumina cement conforming to IS 6542.
3.3 Sand : The sand used shall have a controlled granulometric distribution from
fine to coarser elements. It shall be clean and shall be composed of inert, hard,
strong & stable granular particles. The gradation of sand shall be as specified in
IS 8329.
3.4 Water : The water used for the preparation of mortar shall not contain
substances deleterious to the mortar.
3.5 Zinc : Zinc used for coating purpose is metallic zinc with content of atleast 99
% by mass.
3.6 Bitumen: Bitumen used for coating purpose shall be smooth, tenacious and
hard as specified in IS 8329.
3.7 Polyethylene: The density of polyethylene shall be between 910 to 930 kg/m³.
3.8 Rubber gasket : Rubber gaskets used with push-on joints or mechanical shall
conform to IS5382, whereas rubber gaskets for use with flanged joints shall
conform to IS638.
4.1 The metal used for the manufacture of pipes shall be of good quality,
commensurate with the mechanical requirements laid down of IS 8329.
4.2 The pipes shall be stripped with all precaution to avoid warping or shrinkage
defects, detrimental to their good quality. The pipes shall be sound and free
from surface or other defects.
4.3 Pipes centrifugally cast shall be heat-treated in order to achieve the necessary
mechanical properties and to relieve casting stresses caused due to the method
of manufacture and repair work.
4.4 If necessary, the pipes may be subjected to reheat treatment to ensure that
Brinell hardness dose not exceed the specified value and the other
mechanical properties specified in IS8329 are achieved.
4.5 The manufacturing process flow of DI Pipe is as given the below.
2
Molten Iron
Induction Furnace
Spheroidization
Core Making
Centrifugal Casting
Annealing
Zinc Spraying
Grounding & Grinding
Hydraulic Testing
Cement Lining
Cultivating
Bitumen Coating
Packing
 Pipes have been classified as K7,K8,K9, K10, K12,….depending on service

conditions and manufacturing processes
 The class designation shall comprise of
a) prefix K
b) a whole number used for thickness. class designation
 The wall thickness of pipe ‘e’ in mm shall be calculated as function of the nominal
diameter by the following equation with minimum of 5mm for K=7,6mm for k=8 &
7mm for K=12.
e=K(0.5+0.001DN)
where
e=wall thickness in mm
DN=the nominal diameter, & K=the whole number coefficient.
3
 The value of K will depend on following service conditions.
Service conditions
Nominal Water Sewers Gas main
dia Main
80-300 K9-K12 K7-K12 K9-K12
350-600 K8-K10 K7-K10 K9-K10
700-2000 K7-K10 K7-K10 K9-K10
 For screwed or welded on flange pipes the minimum classes as per working pressure
criteria are given below.
4.7 Coating : DI pipes shall normally be coated externally and internally.

4.7.1 External protection: Depending upon external condition of use , the external
protections can be of following three types as specified in IS 8329.
a) Zinc coating:
 The pipe surface shall be dry and free from rust or any non adhering
particles or foreign matters such as oil or grease. Metallic zinc shall be
applied on to the oxide external surface of the pipe.
 The coating materials are metallic zinc with content of atleast 99% by
mass.
 The metallic zinc coating shall be applied by as spraying process, in which
metallic zinc material is heated to molten state & projected in small
droplets by spray guns onto surface. The zinc rich paint coating shall be
applied by a spraying or a brush process onto the pipe surface in case of
repairs only.
 The metallic zinc coating shall cover the outside diameter of the pipe and
shall be free from such defects as bare patches or lack of adhesion.
 Damaged areas of zinc coating caused by handling are acceptable provided
that the damage is less than 5cm2/m2 of coated surface & provided that the
minor dimensions of the damaged area do not exceed 5mm.
 The average mass of zinc coating shall be not less that 130g/m2 with local
minimum of 110gm/m2
 After metallic zinc coating or zinc paint coating, the pipe shall be given a
finishing layer of bituminous paint or synthetic resin compatible with the
zinc coating.
4
 Applications of the finishing layer may be done by any proven process such
as spraying or brush coating at the manufacturer’s choice. It shall uniformly
cover zinc coating and be free from bare patches or lack of adhesion.
 The mean dry film thickness of the finishing layer shall not be less that
70µm. with nowhere less than 50µm.
b) Bituminous coating :
 Coating shall not be applied to any pipe unless its surfaces are clean,
dry & free from rust.
 The mean thickness of coating shall be not less than 70µm & the local
minimum thickness shall be not less than 50µm.
 Where the coating material has a bitumen base, it shall be smooth &
tenacious and hard enough not to flow, when expose to temperature of 65 0
c but not so brittle at a temperature of 00C as to chip off when scribed with
a penknife.
c) External sleeving :
 The polythelene sleeves may be supplied, for encasement of the pipes at
site, alongwith the pipes if ordered by the purchaser. This encasement
shall be so designed that prevent contact between pipe and surroundings
backfill and bedding material.
 The material used for making the film is polyethylene or a mixture of
polyethylene and /or ethylene and olefin copolymers. Its density shall be
between 910 & 930 kg/m3
 If protection against ultra violet rays is required , the material shall be
stabilized by the additions of an appropriate product, if carbon black is
used for this purpose the addition shall be in the range of 2 to 3 % by
mass.
4.7.2 Internal lining : Depending upon the internal conditions of use, the internal
lining can be of following two types as specified in IS 8329.
a) Cement mortar lining : The cement used for the lining shall be either ordinary
Portland cement or sulphate resisting portland cement or high alumina cement.
 The mortar of the lining shall be composed of cement, sand & water. Additives
, which shall be specified may be used, provided that they do not prejudice the
quality of the coating & that of the transported water. The mortar shall contain
by mass atleast 1 part of cement to 3.5 parts of sand
 All foreign bodies , loose scale or any other material which could be detrimental
to good contact between the metal & the lining shall be removed from the
surface to which the lining is to be applied. The inner surface of pipe shall also
be free of any metal projections likely to protrude beyond 50% of thickness of
the lining.
 The cement mortar lining at works is applied by a centrifugal spinning process
or a centrifuged sprinkler or combination of both methods.
5
 Lining thickness varies from 3mm to 9mm depending on pipe thickness as
specified in IS8329.
 The surface of the cement mortar lining shall be uniformly smooth. Only
isolated grains of the sand are allowed to appear on the surface of the lining.
 When specified, the cement lining shall be given a seal coat of bituminous
material or any other epoxy base material compatible with cement mortar
lining. The purpose of the seal coat is to minimize lime, leaching of the cement
mortar as well as to restrict the unwanted rise in pH value of the transmitted
water.
b) Bituminous paint : The specification for this shall be as given in sub para (b) of
para 4.7.1 above.
 In a consignment, all pipes/ fittings of the same class, type and dimensions
produced by a single manufacturing unit shall constitute a lot. Each lot shall be
inspected separately for ascertaing its conformity to the requirements of
specification given in IS 8329.
 Each pipe shall be checked for visual characteristic such as surface defect, finish
& position of socket, flanges, threads, collars.
 The lot which has been found satisfactory in respect of visual requirements,
shall be tested for dimensional requirements as specified in following para No.
6.0. Numbers of pipes to be selected from the lot for checking dimensional
requirements shall be as per following Table No.1.
Table No.1 Scale of sampling and criteria for acceptance for dimensional
requirements of pipes.
Lot size Sample size Acceptance No.
Upto 50 8 0
51-100 13 1
101-150 20 1
151 -300 32 2
301 & above 50 3
 Each of the items selected according to above para shall be inspected for
dimensional requirements. Any item failing to meet above requirements shall
be termed defective. If the number of defectives found in the sample is less
than or equal to acceptance number given in column 3 of above Table 1, the lot
shall be deemed as conforming to the requirements specified. Otherwise, the
lot shall be rejected or subjected to 100 % inspection for the requirements.
 The lot found conforming in respect of dimensional requirements shall then be
tested for mechanical acceptance tests as specified in following para No.6.
6
 The mechanical acceptance tests shall be carried out on samples of ductile iron
pipes which shall be grouped in following batch sizes.
DN (mm) Maximum Batch Size
80 - 250 200 pipes
300 - 600 100 pipes
700- 1000 60 pipes
1 100 – 1400 40 pipes
1 600 – 2 000 30 pipes
 In order to check compliance with the requirements specified for mechanical

acceptance test, a sample ring or bar shall be taken from the spigot end of
pipes.
 For this purpose, the number of tests for mechanical acceptance tests shall be
at the rate of 1 per 4 tonnes of pipes/ fittings subject to minimum of 2 and
maximum of 10 tests.
 Each pipe and fittings shall be subjected to hydrostatic tests in the factory.
 For coating tests, two samples from each test shall be taken at random &
subjected to appropriate tests. These sample shall meet the coating
requirements as mentioned in para 4.7.
 If test piece representing a batch fails in the test in the first instance, two
additional tests shall be made on test pieces selected from two other pipes
from the same batch. If both the test results satisfy the specified requirements,
the batch shall be accepted. Should either of this additional test pieces fail in
the test, the batch shall be deemed as not complying with the requirement.

Pipe selected as per sampling criteria mentioned in above para 5.0, are subject to
1. Dimension:Critical dimensions, External diameter, Wall thickness, Length of
pipe, ovality,deviation from straight line.
2. Tensile test
3. Brinell hardness test
4.Hydraulic test
of Engineer In-charge /WRD/QC/TPI.
6.1 Dimensions:
Various dimensions of pipes shall be as per the relevant tables of IS.8329 for different
class of pipes.
6.1.1 Critical dimension: Critical dimensions for socket and spigot of pipes for push-
on flexible joints and mechanical joints for classes K7 , K8,K9 & K10 are given in the
following table no.2.
7
Table no.2: Dimensions of sockets & Spigots
All dimensions are in mm
Nominal External Barrel wall thickness ’e’(mm)

diameter diameter K7 K8 K9 K10
DN (mm) DE(mm)
80 98 5 6 6.0 6.0
100 118 5 6 6.0 6.1
125 144 5 6 6.0 6.3
150 170 5 6 6.0 6.5
200 222 5 6 6.3 7.0
250 274 5.3 6 6.8 7.5
300 326 5.6 6.4 7.2 8.0
350 378 6.0 6.8 7.7 8.5
400 429 6.3 7.2 8.1 9.0
450 480 6.6 7.6 8.6 9.5
500 532 7.0 8.0 9.0 10.0
600 635 7.7 8.8 9.9 11.0
700 738 9.0 9.6 10.8 12.0
750 790 9.7 10.0 11.3 12.5
800 842 10.4 10.4 11.7 13.0
900 945 11.2 11.2 12.6 14.0
1000 1048 12.0 12.0 13.5 15.0
1100 1152 14.4 14.4 14.4 16.0
1200 1255 15.3 15.3 15.3 17.0
1400 1462 17.1 17.1 17.1 19.0
1600 1668 18.9 18.9 18.9 21.00
1800 1875 20.7 20.7 20.7 23.00
2000 2082 22.5 22.5 22.5 25.00
 Dimensions of flanged pipes centrifugally cast with screwed on flanges or

welded flanges shall be a part table 3,4,5,& 6 of IS 8329
6.1.2 External Diameter : External diameter (DE) of the spigot end of socket and
spigot pipes is measured circumferentially using a diameter tape. The positive
8
tolerance for external diameter is + 1 mm and applies to all thickness classes of
pipes. The negative tolerance of the external diameter depends on the design of
each type of joint and maximum negative tolerance is as specified in following
Table No.3
Table 3 External diameter DE (mm)
(Reproduced from 8329)
Dn Nominal Tolerance
(1) (2) (3)
80 98 +1,-2.2
100 118 +1,-2.8
125 144 +1,-2.9
150 170 +1,-3
200 222 +1,-3.1
250 274 +1,-3.3
300 326 +1,-3.4
350 378 +1,-3.5
400 429 +1,-3.6
450 480 +1,-3.8
500 532 +1,-4
600 635 +1,
700 738 +1,-4.3
750 789 +1,-4.4
800 842 +1,-4.5
900 945 +1,-4.8
1000 1048 +1,-5
1100 1152 +1,-6
1200 1255 +1,-6.2
1400 1462 +1,-6.6
1500 1565 +1,-7
1600 1668 +1,-7.4
1800 1875 +1,-8.2
2000 2082 +1,-9
9
6.1.3 Wall Thickness
The tolerance on the wall thickness (e) and the flange thicknes (b) of the pipes
shall be as follows :
Dimensions Tolerance (mm)
i) Wall thickness -(1.3+0.001 DN)1
ii) Flange thickness (b) ±(2+0.05b)
6.1.4 Length
The Standard working length of socket and spigot pipes shall be 4 m, 5
m , 5.5m and 6 m and for flanged pipes shall be 4m, 5 m, and 5.5 m. Other
lengths are available by agreement between the manufacturer and the
purchaser.
The tolerance on length of pipes shall be as follows :
Type of Casting Tolerance
(mm)
i) Socket and spigot and plain ± 100
ended pipes
ii) Flanged pipes ± 10
6.1.5 Ovality: Out of roundness of a pipe section; it is equal to 100 {(A 1-

A2)/(A1+A2)}, where A1, is the maximum axis and A2 the minimum axis of the
pipe cross-section.
 Pipes shall be as far as possible circular internally and externally. The
tolerance for out-of-roundness of the socket and spigot ends in the jointing
zone for push-on-joint is given in following Table 4 and for mechanical joint
is given in following Table 5
Table 4 Allowable ovality for push-on-Joint Pipe.
Nominal Diameter Allowable Difference between
DN Minor Axis and DE, Min
(mm) (mm)
(1) (2)
80 to 300 1.0
350 to 600 1.75
700 2.0
750 to 800 2.4
900 to 1000 3.5
1100 to 1200 4.0
1400 to 1600 4.5
10
Table 5 Allowable ovality for Mechanical Joint Pipe
Nominal Diameter Maximum Ovality of
DN Spigot of External
(mm) Diaameter DE
(mm)
(1) (2)
80 to 150 5
200 to 350 10
400 to 500 20
600 to 800 30
900 to 1000 40
1100 to 1400 50
1600 to 2000 60
6.1.6 Deviation from a straight line: The pipes shall be reasonably straight when
the pipe is rolled along gantries, separated by distance approximately two-thirds
the length of the pipe to be checked, the maximum deviation from a straight line
in mm shall not be greater than 1.25 times the length L, in metres of the pipe;
6.2 Tensile Test :

 The thickness of the sample and the diameter of the test bar shall be as
given below.
Castings Thickness Test Bar, Test Bar, Method B

(mm) Method A Nominal Nominal Tolerance on
Nominal Area Sₒ Diameter Diameter
Diameter (mm2) (mm) (mm)
(mm)
Centrifugally Cast Pipes
:
--- less than 6 2.5 5.0 2.52 0.01
---6 up to but not 3.5 10.0 3.57 0.02
including 8
---8 up to but not 5.0 20.0 5.05 0.02
including 12
--- 12 and over 6.0 30.0 6.18 0.03
 A Sample shall be cut from the spigot end of the pipe. This sample may be
cut perpendicular to or parallel with the pipe axis, but in case of dispute the
parallel to axis sample shall be used.
 A test bar shall be machined from each sample to be representative of the
metal at the mid-thickness of the sample.
11
 The test bars shall have a gauge length at least five times the nominal test
bar diameter. The ends of the test bars shall be such that they will fit the
testing machine.
 Two methods of measuring the tensile strength are method A or method B
as explained below:
Method A—Machine the test bar to its nominal diameter +/- 10 percent,
measure the actual diameter before the test with an accuracy of 0.01 mm and
use this measured diameter to calculate the cross- sectional area and the
tensile strength.
Method B—Machine the test bar to its nominal area Sₒ within a specified
tolerance on diameter and use the nominal area to calculate the tensile
strength.
 The sample shall be tested as per procedures laid down in IS 1608. The test
results shall satisfy the following requirements.
Nominal Diameter Minimum Tensile strength Minimum Elongation at break
(DN) (mm) (MPa) (%)
80-1000 420 10
1100-2000 420 7
 For ductile iron pipes upto DN 1000, if the tensile strength of specimen is not
found within limits, and microstructure reveals 75 percent ferrite with
spheroidal graphite and percentage elongation ≥7, it shall be taken as meeting
the requirements.
6.3 Brinell Hardness Test :
When tested in accordance with IS 1500, the Brinell hardness shall not
exceed 230 HB on the external un-machined surface.
6.4 Hydrostatic Test :
 All pipes shall be tested hydrostatically at a pressure specified in following
Table no.6. To perform the test, pressure shall be applied internally and
shall be steadily maintained for a period of 10sec. The pipes shall withstand
the pressure test and shall not show any sign of leakage, sweating or other
defects of any kind.
 Test shall be carried out before the application of surface coating and lining.
12
Table no.6 Hydrostatic Test Pressure
Nominal Minimum Hydrostatic Test Pressure at Works, MPa
Diameter Centrifugally cast pipes with Pipes with screwed or welded on
(DN) (mm) flexible joints flanges
Class K7 Class Class K9, PN PN 16 PN 25 PN 40
K8 Class 10 Flange Flange Flange
K10, Flan
Class ge
K12
(1) (2) (3) (4) (5) (6) (7) (8)
80 to 300 3.2 4.0 5.0 1.6 2.5 3.2 4.0
350 to 600 2.5 3.2 4.0 1.6 2.5 3.2 4.0
700 to 1000 1.8 2.5 3.2 1.6 2.5 3.2 --
1100 to 1.2 1.8 2.5 1.6 2.5 2.5 --
2000

2. Class reference
3. Pressure rating.
4. Nominal diameter
be inscribed.

 DI pipes are less susceptible to cracking or breaking or impact but precautions should
be taken to prevent damage to the protective coating.
 Pipes should be loaded in such a way that they are secured and that no movement
should take place on the vehicle during transit.
 The pipes should be loaded on vehicles in pyramid or straight sided formation. In case
of pyramid loading, the pipes in the bottom layer should be restrained by the use of
broad wooden wedges secured to the vehicle being loaded. The pyramid is to be
formed by resting pipes between the pairs of pieces in the preceding layer with the
sockets in layers reversed. Straight sided loading may be used with supports along the
13
sides of the vehicles. The use of straight sided loading is advantageous for utilizing full
capacity of the vehicle.
 Cranes should be preferred for off-loading. However, for pipes up to 400 mm nominal
bore, skid timbers and ropes may be used.
 When using mechanical handling equipment, it is necessary to employ sufficient
personnel to carry out the operation efficiently with safety. The pipes should be lifted
smoothly without any jerking motion and pipe movement should be controlled by the
use of guide ropes in order to prevent damage caused by pipes bumping together or
against surrounding objects.
 Where the crane operator does not have a clear view, he should be guided by the
personnel supervising the operation. The hooks should be of suitable shape to ensure
positive engagement when entered into the ends of the pipes and then should pass
over any protective packing fitted around the pipe ends.
 The use of slings passed around bundles of pipes is not recommended because
bundles become unstable as the sling is drawn tight or released. However, when it is
necessary to use the central slinging method for lifting single pipe, a broad webbing
sling is recommended which minimizes the risk of the pipe slipping.
9.0 Stacking of Pipe at Site
 The first layer of pipes should be laid on a firm foundation consisting of solid timbers
set level on the ground. Subsequent layers should be placed according to the method
of stacking adopted. Care should be taken so that the pipes do not rest on their
sockets. The height of any stack should not exceed 2 m. Stacking of pipes can be either
square or parallel or nested as explained below.
14
Methods for Stacking of Pipes
Square Stacking Parallel Stacking with Nested (Pyramid)
timbers Stacking
nd  All the pipes are parallel  Nested stacking consists
 2 and subsequent
layers are set at right with the sockets of of placing each pipe
angles to previous successive layers reversed between the two pipes
layer with spigots & end-to-end with sockets underneath it, with the
sockets alternating in projecting beyond spigot sockets being all at one
each layer & sockets end. end of each layer &
project beyond spigot  Timber battens placed about being reversed in
end. 600 mm from each end at successive layers.
 The pipes rest right angles to the pipes are  The bottom layer should
directly upon those used to separate the be firmly anchored to
beneath it. successive layers. prevent the stack
 Care is needed in  Wedges at both ends of each collapse.
placing to prevent batten prevent pipe
damage. movement.
 Bitumen-sheathed pipes should not be stacked but laid in a single layer supported on
timbers placed under the uncoated portions of the spigots and sockets.
10.0 Valves
10.1 Air Valve :

certain velocity, the air valve can discharge the remained gas in the pipe; secondly,
at the normal working stage, the air valve can discharge the small amount of gas
gathered in the pipe timely; finally, during the pump failure or maintenance
stages, the air valve will replenish the gas into the pipe to break the vacuum.
According to the orifice size, displacement and work pressure, air valve is divided
into high pressure trace exhaust valve, low pressure air release valve and
combined air valve.
15
10.2 Scour Valve :
Where the main pipeline crosses a stream or drainage structures, there will usually
be a low point in the line but if the main pipeline goes under the stream or drain,
it cannot be completely drained into the channel. In such a situation it is better to
locate a scour connection at the lowest point that will drain by gravity and provide
for pumping out the part below the drain pipeline.
A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve

16
12.2 Demarcation
control points for these works. The Contractor shall establish sufficient number
of reference benchmarks for facilitating setting out of work and taking levels
for the purpose of measurements.
Engineer-In-charge.
17
3. Levels 2 Nos.
4. Staves 4 Nos.
the materials to be excavated and the difficulties of making and maintaining
than 500 mm.
moist, wet or slushy. The Contractor shall have to excavate the PDN pipe trench
and structure in under water level conditions also i.e. under wet/slushy
18
excavated under water level condition which requires intermediate stacking for
drying shall have to be rehandled. No extra payment for efforts for drying out
of soil, re-handling of dry soil, etc. shall be given. No payment for extra efforts
for excavation under this condition shall be made.
Engineer In Charge and such over excavated section shall be filled with suitable
murum type soil to be placed in uniformly compacted layers as directed by the
Engineer In Charge. The over excavation made in such strata, filling by suitable
soil, and watering and compacting such soil will be paid separately under
relevant items. Above provision for over excavating and filling with suitable
murum type or good soil available material shall be applicable in case such
treatment is found essential.

While laying of DI pipes, all precautions mentioned in IS 12288 shall be taken
 Pipes should be lowered into the trench with tackle suitable for the weight of pipes.
 For smaller sizes, up to 250 mm nominal bore, the pipe may be lowered by the use of
ropes but for heavier pipes, either a well designed set of shear legs or mobile crane
should be used.
 If sheathed pipes are being laid, suitable wide slings or scissor dogs should be used.
 All construction debris should be cleared from the inside of the pipe either before or
just after a joint is made. This is done by passing a pull-through in the pipe, or by hand,
depending on the size of the pipe.
 When laying is not in progress, a temporary end closure should be securely fitted to
the open end of the pipeline. This may make the pipe buoyant in the event of the
trench becoming flooded, in which case the pipes should be held down either by
partial re-filling of the trench or by temporary strutting.
 On gradients of 1:15 or steeper, precautions should be taken to ensure that the spigot
of the pipe being laid does not move into or out of the socket of the laid pipe during
19
the jointing operations. As soon as the joint assembly has been completed, the pipe
should be held firmly in position while the trench is backfilled over the barrel of the
pipe. The backfill should be well compacted.
 The cutting of pipe for inserting valves, fittings, etc, shall be done in a neat and
workman like manner without damage to the pipe or lining so as to leave a smooth
end at right angles to the axis of the pipe. Cutting of pipes can be done either by
hand/power operated hacksaw or manually operated wheel cutter or by pipe cutting
machines.
 The burr left after cutting should be trimmed off by light grinding or by filling.
 At joints, bends and valves, precautions should be taken to provide sufficient overlap
of the wrapping sleeve so that no pipe line is exposed to the aggressive soil.
 All pipelines having unanchored flexible joints require anchorage at changes of
direction and at dead ends to resist the thrusts developed by internal pressure.
 Each pipe shall be checked for any damage before laying and only the pipe which are
approved by the Engineer shall be laid.
 Where pipes are to be bedded directly on the bottom of the trench, it should be
trimmed & leveled to permit even bedding of the pipe line. However while laying in
rocky areas, 150 mm compacted fine sand bedding under and around pipe needs to
be provided.
15.0 Jointing of Pipes-

Jointing of pipes shall be done as per procedure laid down in IS 12288. The
joints are mainly of two type viz.flexible joints & flanged joints.
15.1 Flexible Joint-
 The spigot and socket flexible joint should be designed to permit angular
deflection in direction and axial movement to compensate for ground
movement and thermal expansion and contraction. They incorporate
gasket of elastomeric materials and the joints may be of the simple push-
on-type or the type where the seal is effected by the compression of a
rubber gasket between a seating ring on the inside of the socket & external
surface of the spigot.
 Flexible joints are required to be externally anchored at all changes in
direction such as at bends, at blank end to resist the thrust created by
internal pressure and to prevent the withdrawal of spigots.
20
15.2 Flanged Joint-
 Flanged joints are made on pipes having a machined flange at each end of
the pipe. The seal is usually affected by means of a flat rubber gasket
compressed between two flanges by means of bolts which also serve to
connect the pipe rigidly. Gaskets of other materials, both metallic and non-
metallic, are used for special applications.
 In case of ductile iron pipes with screwed on flanges or welded flanges, the
flanges shall be at right angle to the axis of the pipe and shall be machined
on face. The bolt holes shall be either cored or drilled.
15.3 Jointing Procedure-
 Procedure for jointing will vary according to the type of joint being used.
Basic requirements for all types are:
a) Cleanliness of all parts,
b) Correct location of components,
c) Centralization of Spigot within socket, and
d) Strict compliance with manufacturer's jointing instructions.
 The inside of sockets and the outside of spigots should be cleaned and wire
brushed for a distance of 150 to 225 mm.
 Glands & gaskets should be wiped clean and inspected for damage.
 When the pipeline is likely to be subjected to movement due to subsidence
or temperature variations, the use of flexible joints is recommended. A gap
21
should be left between the end of the spigot and the back of socket to
accommodate such movement.
16.0 Field Testing of Pipeline System

16.1 General
 All pipelines should be tested before being brought into service. The test
 After a new pipeline is laid and jointed, testing shall be done for:
a) mechanical soundness and leak tightness of pipes and fittings;
b) leak tightness of joints; and
c) Soundness of any construction work, in particular that of the
anchorages.

The test pressure to be applied should be not less than any of the following:
a) The maximum sustained operating pressure,
b) The maximum static pressure plus 5 N/mm2, and
c) The sum of the maximum sustained operating pressure (or the
maximum static pressure) and the maximum calculated surge pressure.
16.3 Test Procedure
 The completed pipeline may be tested either in one length or in sections;
the length of section depending upon:
a) availability of suitable water,
b) number of joints to be inspected, and
c) difference in elevation between one part of the pipeline and another.
 Where the joints are left uncovered until after testing, sufficient material
should be backfilled over the centre of each pipe to prevent movement
under the test pressure.
 It is prudent to begin testing in comparatively short length of test section.
Progressively as experience is gained, lengths of about 1.5 km or more, are
tested in one section, subject to consideration of length of trench which can
be left open in particular circumstances.
 Each section should be properly sealed-off. Preferably with special stop
ends secured by adequate temporary anchors. All permanent anchors
should be in position and, if of concrete, should have developed adequate
strength before testing begins. The section under test should be filled with
22
water, taking care that all the air is displaced either through vents at the
high points or by using a pig or a sphere.
 After filling, the pipeline should be pressurized to the specified operating
pressure and left for a period of time to achieve stable conditions. The
length of this period of time depends on many factors such as slight
movement of the pipeline under pressure whether air is trapped in the
pipeline or whether the pipeline has a concrete lining which absorbs water.
 The pipeline is then pressurized up to the full test pressure and the section
under test completely closed off. The test should be maintained for a period
of not less than 10 minutes to reveal any defects in the pipes, joints or
anchorages.
16.4 Leak Detection Test

 If the test is not satisfactory, the fault should be found and rectified. Where
there is difficulty in locating a fault, the section under test should be
subdivided and each part tested separately.
If any leakage is found during testing of pipeline, Contractor will have to

attend the same immediately and rectify at his cost. If Contractor fails to
rectify the defect, the entire length of pipeline between two adjacent
Contractor for portion under rejection, the same shall be recovered from
the outstanding dues of the Contractor.
16.5 Final Testing:
 After all sections have been joined together on completion of section
testing, a test on the complete pipeline should be carried out. This test
should be carried out at a pressure not less than the maximum sustained
operating pressure or the maximum static pressure of the pipeline and,
during the test, inspection made of all work which has not been subject to
section tests. During the test, the pressure at the lowest point in the pipeline
should not exceed the maximum given in following Table no. 7.
23
Table no-7 Maximum Field hydrostatic test pressure for ductile iron
pipelines with flexible joints
the material, shall be subject to approval by the Engineer-in-Charge.
drawings or as prescribed in this paragraph or as directed by the Engineer-in-
Charge.
up as uniformly as practicable on both sides of pipe to prevent unequal loading.
cured. The size and weight of equipment will depend on nature of material, the
height and load assumed in design of structure. The backfill close to the
using pneumatic / hand tampers as appropriate for dry density at average bulk
density (+/- 10%). The moisture content of the earth fill placed against the rock
or the structure shall be on higher/lower side of OMC by about 2% or so, to
allow it to be compacted. Profuse watering shall be done to pervious materials
(sand) before compaction as per instruction of the Engineer-in-Charge.
24
Compaction at junction of earthwork and backfill around the structure shall be
carried out with special care.

of this block shall be buried in ground projecting only 15cm above the ground
18.4 The contractor shall show all this blocks jointly to the Engineer-in-charge or his
18.8 The Geo-tagging map showing Latitude and Longitude value of each apex of
as directed by Engineer-in-charge. On these boards, salient features of the work
(e.g. Pipe diameter, pipe type, discharge, any other specific details suggested by
25

3 S.G.S, Mumbai
5 VJTI, Mumbai
26
Contractor.
Engineer in charge.
Sr.
No.

generation work)
2 Laboratory Assistants(Twevlth Pass with Two to Four

testing of material) (As per work)
(One for each L.A.)
27
by the contractor.
Sr.
No.

Sieves for Sand & Metal.
Field testing Equipments


sand, coarse aggregates etc. shall be carried out in field laboratory set up by
the contractor in presence of quality control representative at contractors
20.5 The materials, mixes and any other arrangements, including labours, shall be
supplied by the contractor. The samples for testing shall be taken in the
report (Weekly/fortnightly/monthly) to Engineer in Charge along with proofs in
support of quality of material brought for the work, the process/ execution of
work is as per specification.
20.7 Contractor shall submit the account of all materials brought for the work, which
are necessary for execution of work and any other data necessary to assess the
quality of work.
28
and field laboratory with required equipments will be deployed by the Engineer
in charge and the charges for the same will be recovered from the contractor.
from any damages.
Geotagged map of laid pipeline shall also be handed over to WUA.
the release of designed discharge through every outlet before handing over. In
case of any short fall or defect, it should be made good from the contractor at
his own cost.
22.1 Measurement
29
22.2 Payment




----------***----------
30
SPECIFICATIONS FOR
SPIRALLY WOUND STEEL
REINFORCED PIPES (SWSRP)
2020
0
SPECIFICATION FOR SPIRALLY WOUND STEEL REINFORCED PIPES (SWSRP)
1.0 Introduction
The Spirally Wound Steel Reinforced Pipes (SWSRP) are structured wall
pipes comprising of an HDPE inner smooth layer, spiral steel skeleton and
outer corrugated profile of HDPE. This pipe utilizes a state – of – the – art
manufacturing process which results in a product which has an excellent
external overburden bearing capacity and internal pressure sustenance.
The Contractor shall provide on-site training on SWSRP pipe laying,

jointing, testing and maintenance etc., to the personnel authorized by Engineer-
in-Charge. The contractor should provide technical Manual on SWSRP pipes
including precautions to be taken during operation of the pipeline.
SWSRP Pipes
2.0 Applicable IS Codes, ISO Codes
of SWSRP pipes shall comply with all currently applicable statutes, regulations,
specified herein, shall be referred. In all cases the latest revision of the Codes
shall be referred to. If requirements of this Specification conflict with the
requirements of the standards/Codes, this Specification shall govern. Others
Codes not specifically mentioned here but pertaining to the use of SWSRP Pipes
form part of these Specifications.
1
IS 2530: 1963 Methods of test for polyethylene molding materials and
polyethylene compounds
IS 7328 : 1992 High DENSITY polyethylene materials for moulding and
extrusion
ISI 12235 (Part6) - Thermoplastic pipes and fittings methods of tests part 6 :
2004 Stress relief test
ISI 12235 (Part 9) Thermoplastic pipes and fittings methods of tests part 9 :
- Resistance to external blows
2004
IS 16098 Part- Structured wall Plastics Piping Systems for Non pressure
I:2013 drainage & Sewerage - Pipes and fittings with smooth
external surface
IS 16098 Part- Structured wall Plastics Piping Systems for Non pressure
II:2013 drainage & Sewerage- Pipes and fittings with non-smooth
external surface
3.0 Raw Materials

 Raw material used to manufacture Pipes is Polyethylene, to which may be
addedthose additives that are needed to facilitate the manufacture of
pipes and fittings conforming to the requirements mentioned in following table 1.
Table No.1 Material characteristics for PE material. ( reproduced from IS 16098)
Sr. No. Test Parameter Requirement Test method
1 Base Density ≥ 0.930 g/cc As per IS 7328
2 Melt Flow Rate ≤1.6g/10minutes. As per IS 2530
3 Thermal Stability(Oxidation ≥ 20 minutes As per IS

Induction Test) 16098(part 2)
 The addition of the manufacturer’s own rework material (Clean &

reprocessable) is permissible. The quantity of rework material used is
to be declared by the manufacturer. No other rework material shall be
used.
The General manufacturing process of SWSRP Pipe is as given below.

 The steel strip is washed in hot water to remove oil, grease or
any other contamination.
 The steel strip is then coated with high performance adhesive.
 The HDPE granules and the additives are mixed in batches.
 The material is fed into the extruder hopper through a spiral flow
conveyer and hopper
2
 The material gets molten in the heating zone of the extruder, which is
then
extruded into pipes passing through a mandrel/die arrangement.
Different mandrel/die combinations are used for different pipe sizes.
 Corrugated Spiral Pipes, smooth inner surfaces, outer surfaces are made
so that the profile on Larger Diameter Corrugated Pipes
 During forming of pipe the steel strip is encapsulated within the
corrugations between polyethylene to form high strength pipe.
 The extruded pipe is passed through a traction (also called hauling)
arrangement to extract the pipe at a regulated speed. This also controls
the dimensions of the pipe.
 The pipes are then cut to size in a cutter
 One end of the cut pipes is then processed for socketing.
4.1 Classification of Pipes:

The pipe shall be designated in the following nominal ring stiffners
classes (SN).
a) Nominal size (DN) ≤500: SN 4, SN 8 or SN 16

b) Nominal size (DN) ≥ 500: SN 2, SN 4, SN 8 or SN 16

All SWSRP pipes in a single consignment of the same class, same size and
manufactured under essentially similar conditions shall constitute a lot. The
number of test samples to be taken from a lot shall depend on the size of
the lot and shall be in accordance with following Table No. 2 & 3.
Table No.2 Scale of Sampling for Visual Appearance and Dimensional

Requirements. (Reproduced from IS 16098)
3
Table No.3 : Scale of sampling for test other than visual and dimensional
requirements ( reproduced from IS 16058)
No of pieps in lot Sample size for Sample size for
ID ≤ 500mm ID ≥ 500mm
Upto 1000 2 1
1001 to 3000 3 2
More than 3000 4 3
These pipes shall be selected at random from the lot and in order to ensure
the randomness of selection, a random number table shall be used.
5.1 The dimensional and visual requirements:

The number of pipes given for the first sample in column 3 of above Table
No.2 shall be taken from the lot and examined for visual and dimensional
requirements given in para No.6 below. A pipe failing to satisfy any of these
requirements shall be considered as defective. The lot shall be deemed to
have satisfied these requirements, if the number of defectives found in the
first sample is less than or equal to the corresponding acceptance number
given in col. 5 of Table 2. The lot shall be deemed not to have met these
requirements, if the number of defectives found in the first sample is greater
than or equal to the corresponding rejection number given in col 6 of Table
2. If, however, the number of defectives found in the first sample lies
between the corresponding acceptance and rejection numbers given in col 5
and 6, a second sample of the size given in col 3 shall be taken and examined
for these requirements. The lot shall be considered to have satisfied these
requirements if the number of defectives found in the cumulative sample is
less than or equal to the corresponding acceptance number given in col 5,
otherwise not.
5.2 The lot having satisfied the dimensional and visual requirements shall be
tested for other requirements mentioned in para 6.0 below with the sample
size selected as per Table No.3 above. The lot shall be considered to have met
the requirements of these tests, if none of these samples tested fails.

Pipe selected as per sampling criteria mentioned in earlier para 5.0 are subject
to following tests before delivery from factory
1. Dimension: Length, Diameter of pipe.
2. Visual Appearance,
3. Colour of Finished Pipe,
4. Physical Characteristics
5. Mechanical Characteristics.
These test shall be carried out by the contractor in the presence of
representative of Engineer In-charge /WRD/QC/TPI.
4
6.1 Dimensions
6.1.1 Length:
The length of pipe shall be 4, 5 or 6 m. The pipe may be supplied in
other lengths, as agreed between the manufacturer and the
purchaser
6.1.2 Diameter of pipe
The internal diameter (DN/ID) shall be as per table No.4
Table 4 : Nominal sizes shall be as per Table 4 : Nominal sizes , minimum means
inside diameters, thickness of inside layer ( reproduced from IS 16058)
SI No. DN/ID Series Minimum Wall Thickness

DN/ID dim,min e4,min E5,min
mm mm mm
1 2 3 4 5
i 75 71 1.0 0.85
ii 100 95 1.0 1.0
iii 125 120 1.2 1.0
iv 135 130 1.2 1.0
v 150 145 1.3 1.0
vi 170 165 1.4 1.0
vii 200 195 1.5 1.1
viii 225 220 1.7 1.4
ix 250 245 1.8 1.5
x 300 294 2.0 1.7
xi 400 392 2.5 2.3
xii 500 490 3.0 3.0
xiii 600 588 3.5 3.5
xiv 800 785 4.5 4.5
xv 1000 985 5.0 5.0
xvi 1200 1185 5.0 5.0
5
The structured outer layer of finished pipes shall be uniformly corrugated.
The inner layer shall be smooth and plain. Both layers shall be free from any
visual defects such as cracks, blisters, foreign inclusions and any other visual
irregularities which may cause harm to its construction integrities. The inner
surface may reflect slight shallow undulation.
6.3 Colour of Finished Pipe
Colour of Finished Pipes shall be declared by manufacturer. The colour of
outer layer should be preferably black.
6.4 Physical Characteristics of Pipes

When tested in accordance with the test methods specified in IS
12235(part 6) using the indicated parameters, the pipe shall have
physical characteristics conforming to the requirement given in Table
5.
Table 5 Physical Characteristics of PE Pipes (Reproduced from IS 16098 Part-II)

Characteristic Requirements Test Parameters
Resistance The pipe shall Temperature (110 ± 2) °C

to heating show no Immersion time
oven test delamination, for e ≤ 8 mm
cracks or and e > 8 mm 30 min
bubbles 60 min
For the wall thickness, e, the maximum measured wall thickness of the pipe excluding ec shall be
taken
6.5 Mechanical Characteristics

When tested in accordance with the test methods specified in IS 16098
and IS 12235 using the indicated parameters, the pipe shall have
Mechanical characteristics conforming to the requirement given in Table
6.
6
Table 6 Mechanical Characteristics (Reproduced from IS 16098 Part-II)
Characteristic Requirements Test Parameters Test

Methods
Ring Stiffness ≥ relevant SN In accordance with Annex C of IS 16098 As per Annex
(Part 1) C of IS 16098
(Part 1)
Impact strength TIR ≤ 10 % a) Type of striker d 90

b) Mass of striker for:
1) dim,Max ≤ 100 mm 0.5 kg
2) 100 < dim,Max ≤ 125 0.8 kg IS 12235
3) 125 < dim,Max ≤ 160 1.0 kg (Part 9)
4) 160 < dim,Max ≤ 200 1.6 kg
5) 200 < dim,Max ≤ 250 2.0 kg
6) 250 < dim,Max ≤ 315 2.5 kg
7) dim,Max > 315 3.2 kg
c) Fall height of striker:
1) dim,Max ≤ 100 1600 mm
2) dim,Max > 100 2000 mm
Ring In accordance with Deflection position of 30 percent mould As per Annex

Flexibility Cl. 8.1.2 of IS 16098- test piece split line, when D of IS 16098
2 at 30 percent of dem applicable, at 0°, (Part 1)
45º and 90º from
the upper plate
Creep ratio ≤4 at 2 year As per Annex E of IS 16098 (Part 1) As per Annex

extrapolation E of IS 16098
(Part 1)
3. Pressure rating.
4. Nominal diameter
be inscribed.
7
 When transporting pipes, flat bed vehicles should be used. The vehicle
should be free from nails and other projections. Pipes should rest
uniformly on the vehicle over the whole length.
 The pipes should be secured effectively during transport.
 When loading spigot and socket pipes, the pipes should be stacked on the
vehicle so that the socket do not take excessive loads.
 Mechanical lifting equipment used for lifting pipes and pipe bundles
should not damage the pipe. Loading boom or fork lift should not be used
directly on or inside the pipe.
 The arrangement of loading the pipes in the truck in a telescopic manner
(i.e. smaller diameters inserted in next higher sizes) is advised.
 If pipes have been telescoped for transporting, the inner pipes should be
removed first and stacked separately.
8
9.0 Stacking of Pipes at Site
Following precautions shall be taken so as to eliminate potential damage to

Pipes.
 The area selected for stacking should be plain and care is to be taken to
remove any pointed objects / stones from the area.
 Pipes shall be smoothly lowered to ground.
 Pipes should not be dragged against the ground to avoid the damages to
the pipes.
 Stacking shall done on a flat clear area as shown below.
 Stack height should not be higher than 2.5 m.
 The stacks should be covered with an LDPE Sheet to avoid direct
exposure to sunlight.
Stacking of pipes Stacking of socket and coupler ends
10.0 Valves
For PDN work, various Valves as mentioned below are required to be provided
on pipeline at various location.
10.1 Air Valve :

three areas: firstly, in the waterfilled stage of the pipeline, filled with water
by a certain velocity, the air valve can discharge the remained gas in the pipe;
the vacuum. According to the orifice size, displacement and work pressure,
air valve
9
is divided into high pressure trace exhaust valve, low pressure air release
10.2 Scour Valve :

These Valves are generally provided to drainout the pipeline. The exact
location of Scour valves is frequently influenced by opportunities to dispose
off the water. Where the main pipeline crosses a stream or drainage
structures, there will usually be a low point in the line but if the main pipeline
goes under the stream or drain, it cannot be completely drained into the
channel. In such a situation it is better to locate a scour connection at the
lowest point that will drain by gravity and provide for pumping out the part
below the drain pipeline.
control of flow rate and the consequential control of process quantities
such as pressure, temperature, and liquid level.
A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve

charge, shall be conducted on random samples of pipes collected from site. These test
shall be as per those given in para forgoing No.6.0
The Contractor shall clear the entire area required for setting out.
All tree stumps, roots, brushwood, rubbish of all kinds, loose stones and
all other objectionable materials shall be removed by the Contractor.
Buried irrigation pipeline, and other structure, if any, shall be removed by
the Contractor. The ownership of all the usable material, so removed from
clearing site and/or excavation shall rest with the Engineer In-charge.
Useful material shall be
10
stacked as directed. The Contractor shall dispose off all unusful materials
as directed by the Engineer In-charge.
12.2 Demarcation
marking out slopes, and labour required for line out should be provided
by the Contractor at his own cost. The center line of excavation shall be
clearly marked by pegs or by stones at each chain or change of direction
or at shorter intervals on curves, in the beginning. The final line out will
be done by fixing reference stone at suitable distances on either side of
the center line, beyond the canal edges so that they are not disturbed
during the construction period. The position of these stones will be
marked on the cross section.
12.3 Contractor shall provide and maintain the quarry roads and temporary
roads required for construction activity at his own cost.
approved by the Engineer In-Charge. The benchmark concrete block shall
be 200mm x200mm x600mm with 400mm embedded in the firm ground
and 200 mm projecting above ground. The word ‘BM’ showing value of
R.L. in ‘m’ shall be conspicuously carved and painted on the benchmark.
reference lines shall be fixed and correlated by the Contractor. The
(d) All materials, labour and equipments (theodolites, levels, distometre, etc.)
for setting out works including construction of benchmarks in concrete,
reference lines, check profiles and surveys as may be required at the
various stages of construction shall be supplied by the Contractor at his
cost. For this following numbers of minimum equipments shall be
provided and maintained in good working condition by the Contractor.
3. Levels 2 Nos.
4. Staves 4 Nos.
11
All equipments shall be of standard and approved make and precision, and shall be
made available in advance of starting of the work. All equipment shall be
maintained, repaired and got tested and certified as and when required for its
accuracy from the standard test houses or from the manufactures and to the
satisfaction of the Engineer-In-Charge.
responsibility for deductions and conclusion made by him as to the nature of the
materials to be excavated and the difficulties of making and maintaining the
required excavation. The trench width at bottom shall be 300 mm more than 1.5
times outside pipe diameter. In any case trench width shall not be less than 500
mm.
13.2 The usable excavated material available from the excavated trenches (PDN) shall
be used in backfilling. If such usable material is in excess of the requirement of
backfilling, the same shall be deposited in the spoils as and where directed by the
Engineer In-charge. Unusful material from excavation shall be deposited in spoils
as and where directed by Engineer-In-charge.
13.3 Surface or sub-soil water met with during trench excavation (PDN) and structure
excavation shall be diverted to nearby drain/nalla by cutting an open channel
from trench. When the drain/nalla bed is higher than the sub-soil water level met
with, the bailing out by suitable means of pumping shall be resorted to for
dewatering sub-soil water below the drain/nalla bed level. No distinction shall be
made as to whether the material being excavated is dry, moist, wet or slushy.
The Contractor shall have to excavate the PDN pipe trench and structure in under
water level conditions also i.e. under wet/slushy condition after providing
sufficient arrangement of dewatering. The material excavated under water level
condition which requires intermediate stacking for drying shall have to be
rehandled. No extra payment for efforts for drying out of soil, re-handling of dry
soil, etc. shall be given. No payment for extra efforts for excavation under this
condition shall be made.
for additional excavation as stated here in above or as may be directed by the
Engineer-In-charge, shall be rectified at the cost of the Contractor. Filling and
compaction for such over excavation using the material as directed by the
Engineer In- Charge shall also be at the cost of the Contractor.
13.5 In the PDN and structure section where expansive type of the soil such as CH type
of soil is encountered and over which PDN cannot be directly laid, the PDN trench
and structure shall be over excavated to the extent as directed by the Engineer
In Charge and such over excavated section shall be filled with suitable murum
type soil to be placed in uniformly compacted layers as
12
directed by the Engineer In Charge. The over excavation made in such
strata, filling by suitable soil, and watering and compacting such soil will be
paid separately under relevant items. Above provision for over excavating
and filling with suitable murum type or good soil available material shall be

While laying of SWSRP Pipes, all precautions as mentioned below shall be
taken.
14.1 Each pipe shall be thoroughly checked for any damages before laying and only
14.2 The pipe line may be laid along side of the trench and jointed there. There after
the jointed pipeline shall be lowered into the trench carefully without causing
undue bending. The pipeline shall be laid inside the trench with a slack of up to
2 m/100 m of pipe line.
14.3 Polyethylene pipes being black in colour, when subjected to direct sunlight or
warm ambient temperature may become warmer than the ground temperature.
When placed inside the trench, the pipe will contract in length as it cools to the
surrounding soil temperature. If the pipe is connected to sub- surface structures
(such as preset valve, etc) before it is cooled sufficiently, excessive pull forces
could develop. Allow the pipe to cool to ambient temperature prior to making a
connection to an anchored joint.
14.4 Polyethylene pipe requires no special bed preparation for laying the pipe
underground, except that there shall be no sharp objects around the pipe.
However, while laying in rocky areas suitable sand bedding should be provided
around the pipe and compacted. 100 mm compacted fine sand bedding under
and around the pipe be provided in rocky areas.
14.5 During the pipe laying of continuous fusion jointed systems, due care and
allowance should be made for the movements likely to occur due to the thermal
expansion/contraction of the material. This effect is most pronounced at end
connections to fixed positions (such as valves etc.) and at branch connections.
14.6 The flexibility of polyethylene pipes allows the pipe to be cold bend. The fusion
jointed PE pipe is also flexible as the plain Pipe. Thus the total system enables
directional changes within the trench without recourse to the provision of
special bends or anchor blocks.
14.7 The pipe shall be laid on a stable foundation. Where water is present or where
the trench bottom is unstable, excess water should be removed before laying
the pipe. In case there is a chance of floatation because of likely flood, the pipe
shall be encased with concrete weights as per the buoyancy calculations.
14.8 Polyethylene pipes are non-metallic, so once buried, metal detector type
locators are ineffective. To facilitate locating a buried PE pipe, metallic locating
tapes or copper wires can be placed alongside the pipe. Locating
13
tapes/wires are placed slightly above the crown of the pipe before the
final back fill.

Jointing of SWSRP Pipes are done by electro-fusion process.
The electrofusion joint provides homogeneous joint in between sockets and

spigots. In the electrofusion joints, the main element is electrofusion coil.
The coil is attached to the internal surface of socket and the same has been
stapled to the surface. The terminals are taken out for electric supply. The
spigot should be plain and free from oil, grease etc.
At the time of jointing, the spigot should be inserted into the socket having
coil stapled inside the same. The assembly of these should be then clamped
using chain system. The electric supply provided will generate the heat and
will result in the perfect welding of the socket and spigot.

16.1 The pipeline to be tested shall be filled with water slowly allowing for
splurging the entrapped air. Air valves at high points should be open to
allow air to escape while water is being filled. Before pressure is applied,
the pipeline section under test shall be restrained against movement.
The following procedure needs to be followed for SWSRP pipe testing

a) Polyethylene pipelines shall be pressure tested at ambient
temperature. After filling with water the pipeline shall be left to
stabilize for a period of 1 hour.
b) Fusion joints may be covered during testing. Flanged joints shall be
kept open for visual inspection. The pipeline shall be filled with water
and pressure tested from the lowest point.
c) During the test period, make-up water is continuously added to
maintain the pressure.
14
d) The test pressure shall be 1.5 times the rated pressure of pipes or of
the proposed maximum design pressure of the section. Apply the
pressure by continuously pumping at a constant rate.
e) Tests should be performed on reasonable lengths of pipelines. Long
lengths more than 2 000 m may make leak detection more difficult.
f) Acceptance criteria — If the pressure remains steady (within 5 percent
of the target value) for 1½ h, leakage is not indicated.
g) If the test is not complete because of leakage or equipment failures,
the test section shall be depressurized and allowed to relax for at least
8 h, before starting the next testing sequence.
16.2 If any leakage is found during testing of pipeline, Contractor will have to
attend the same immediately and rectify at his cost within. If Contractor
fails to rectify the defect, the entire length of pipeline between two
adjacent outlets shall be rejected. If any intermediate payment is made to
the Contractor for portion under rejection, the same shall be recovered
from the outstanding dues of the Contractor.

material, shall be subject to approval by Engineer-in-Charge.
matters etc. shall be used for refilling trench upto 300mm above top of pipe. If
sufficient quantity of suitable (Sharp edge stone free) excavated earth is not
available, the trench shall be filled by borrowed gravel material upto 300 mm
above top of pipeline. Remaining trench can be filled with available material.
special care.
15

18.1 The contractor shall establish the sufficient number of reference blocks
on the alignment of PDN preferably at the interval of 30m or as suitable
on the field boundaries so as they will not be disturbed during the
agricultural activities of the farmers.
(15x15x45)CM embeded in concrete block of size (30x30x30)CM. The
base of this block shall be burried in ground projecting only 15cm above
the ground and the base concrete block.
18.3 These blocks shall be able to locate the pipeline as and where it is laid all
over the work. The contractor shall mark each block with specific distinct
18.4 The contractor shall show all this blocks jointly to the Engineer incharge
or his representative, representative of WUA, concern farmers sharing the
18.5 Contractor shall maintained these blocks in proper order during operation
& maintance period of this contract. Any damage done to these blocks for
18.7 The map of marking of the block shall be handed over to WUA while
handing over the command area.
18.8 The Geotagging map showing Latitude and Longitude Value of each apex
of laid pipeline shall be submitted to Department and WUA for future
reference.
location as directed by Engineer-in-charge. On this boards, salient features
of the work (eg. Pipe diameter, pipe type, discharge, any other specific
details suggested by Engineer-In-Charge) shall be written.

Modalities of PMC / TPI / QC Inspection shall be separately decided and
given by Engineer In-charge.
Project management consultants (PMC) should have approved
laboratories certification or collaboration with N.A.B.L. (National
Accreditation Board for Testing and Calibration Laboratories)
Third party Inspection can be done form any one of the following
services
3 S.G.S, Mumbai
16
5 VJTI, Mumbai

latest editions of relevant IS Codes and determined by the Engineer In-
mixes and placed concrete, mortar etc. shall be specified by the Engineer In-
charge from time to time and the Contractor shall provide free of cost all
control authorities for test shall be provided free cost of by the contractor.
Contractor.
labours and other equipment to collect the samples, the same shall be taken
by the Engineer In-charge, and the samples selected shall be considered as
authentic. The cost incurred by the Engineer-In-charge when the Contractor
fails to provide required men and materials for collecting samples and or
their transport shall be recovered from the Contractor.
17
20.1 On award of contract, the Contractor will have to provide adequate
quality assurance setup including Quality Assurance Engineer backed with
suitable laboratory assistants, labours and well equipped laboratory for
taking necessary field test required as per specifications and as per
instructions of Engineer in charge.
20.2 Following minimum persons shall be employed by the contractor at work
site for Quality Assurance.

generation work)
Two to Four
(As per work)
(One for each L.A.)
minimmun equipment shall be available in the field laboratory by
20.3 e contractor setup

Slump, & Cube Moulds, CTM
Charge, the same shall be carried out at the laboratory, selected by
the Engineer-in-Charge at Contractor’s cost. The other tests of mortar,
ng concrete, sand, coarse aggregates etc. shall be carried out in field
laboratory
m set up by the contractor in presence of quality control
representative
F at contractors cost. Contractor shall through this procedure
assure
o the quality of work.
20.5 The
l materials, mixes and any other arrangements, including labours, shall
be
l supplied by the contractor. The samples for testing shall be taken in the
presence
o of Engineer-in-Charge or his representative /QC present on site.
The
w contractor or his authorized representative shall have a free access
in
i these laboratories, to get himself satisfied about procedures of testing
etc.
n Even if the contractor or his representative fails to remain present
while
g collecting samples or testing, the results will be considered as
18
desired from the NABL (National Accreditation Board for Testing &
Calibration Laboratories) approved laboratories and from Quality Control,
MERI laboratories of the WRD. Contractor shall provide periodical quality
assurance report (Weekly/fortnightly/monthly) to Engineer in Charge
along with proofs in support of quality of material brought for the work,
the process/ execution of work is as per specification.
which are necessary for execution of work and any other data necessary
to assess the quality of work.
20.8 If he fails to fulfill the above requirement, the required manpower for
testing and field laboratory with required equipments will be deployed by
the Engineer in charge and the charges for the same will be recovered
from the contractor.

period, during last two years the operation of the schemes shall be done
by the contractor jointly along with WUA. On completion of O & M period,
the system shall be handed over to WUA
hydraulic test to the satisfaction of Engineer In-charge to verify the flow
of designed discharge, detect or confirm any leakage in the system and
rectify at his own cost. The testing shall preferably be conducted jointly
with members of WUA/representative of Engineer In-charge, technical
representative of contractor and any other stake holder.
21.3 On completion of every Irrigation season, the contractor shall flush the
pipe line from its tail flush valve so that any siltation, vegetation or
obstruction is cleaned and pipe is able to flow designed discharge for next
season.
21.5 The contractor shall prepare a detail map of the permanent marking along
the alignment of pipe and submit the same to Engineer In-charge. The
Engineer In-charge shall verify and endorse the location of the marking
and handover these signed maps as a permanent record to WUA. Along
with this, the detailed Geotagged map of laid pipeline shall be handed
over to WUA.
21.6 In association of the members of WUA, the Engineer In-charge shall
confirm the release of designed discharge through every outlet before
handing over. In case of any short fall or defect, it should be made good
from the contractor at his own cost.
19
22.1 Measurement
correct to a cm. Specials shall be excluded and measured in running
meters or numbers as specified by Engineer-in-charge and paid for
separately under the relevant item. The portion of the pipe overlapped at
the joints shall not be included in the length of pipe work. Excavation,
refilling, anchor blocks, thrust blocks wherever required shall be
measured and paid for separately under relevant items of work.
22.2 Payment
The break up to payment for supplying, laying and jointing of pipes shall
be as under:-
Jointing and third party inspection of pipes in one WUA area.
B) Balance 10% of the payment will be released after satisfactory
hydraulic testing of pipeline and backfilling of trenches.
A certificate regarding smooth working of pipe distribution network from
the Chairman of WUA shall be binding for annual release of this amount.
----------***----------
20
SPECIFICATIONS FOR
UNPLASTICIZED POLYVINYL
CHLORIDE PIPES (PVC-O)
2020
SPECIFICATION FOR UNPLASTICIZED POLYVINYL CHLORIDE PIPES (PVC-O)
1.0 Introduction
Technology for manufacturing pipes, which involves process of controlled
circumferential and axial orientation of molecular structure resulting in formation of
laminar structure of the material used in the pipe construction, is commonly known
as PVC-O (Polyvinyl Chloride - Oriented). Manufacturing of pipes by this technology
increases performance and strength of pipes.
The Contractor shall provide onsite training on PVC-O pipe laying, jointing, testing
and maintenance etc., to the personnel authorized by the Engineer-in-charge. The
contractor should provide technical Manual on PVC-O pipes including precautions to

The manufacturing, testing, supplying, laying, jointing and testing at work sites of PVC-
O pipes shall comply with all currently applicable statutes, regulations, standards and
be referred. In all cases, the latest revision of the Codes shall be referred to. If
mentioned here but pertaining to the use of PVC-O Pipes form part of these
Specifications.
IS - 4669 Methods of test for polyvinyl chloride resins

IS - 4985 Unplasticized PVC pipes for potable water supplies
IS - 5382 Rubber Sealing rings for gas mains, Water mains and Sewers
IS - 7634 Laying and jointing of UPVC pipes
(Part-3)
IS - 10151 Specification for polyvinylchloride (PVC) & its copolymers for its safe use
in contact with foodstuffs pharmaceuticals& drinking water.
IS - 12235 Methods of tests for unplasticized PVC pipes.

IS - 16462 Plastic piping and ducting systems- Determination of the long term
hydrostatic strength of thermoplastics materials in pipe form by
extrapolation
IS - 16647 Oriented Unplastized Polyvinyl Chloride (PVC-O) pipes for water
supply.
D:\POOJA\HANDBOOK FINAL\HANDBOOK VOLUME II\10 O-PVC SPECIFICATIONS print copy.docx

01
3.0 Raw Material
3.1 Material
The Material from which the pipe is produced shall consist substantially of
unplasticized polyvinyl chloride to which may be added only those additives that
are needed to facilitate the manufacture of the pipe and the production of
sound and durable pipe of good surface finish, mechanical strength and opacity
under conditions of use. None of these additives shall be used separately or
together in quantities sufficient to constitute a toxic organoleptic or microbial
growth hazard.
3.2 Rework Material
The use of the manufacturer`s own reprocessed material produced during the
manufacture and works testing of products and conforming to the material
requirements of this standard is permitted. Reprocessed or recycled material
obtained from external sources shall not be used.
3.3 VCM content
The monomer content (VCM content) in the resin shall be within the limits
specified in IS 10151
3.4 K-value
The composition shall be based on PVC resin having a K-value of 64 or greater,
when tested in accordance with IS 4669.
3.5 Density
When determined in accordance with IS 12235, the density of the pipe
shall be between 1.40 g/cc and 1.46 g/cc.
3.6 Material Classification

Based on the minimum required strength (MRS) values, the material shall be
classified in accordance with following Table No. 1
Table No. 1 Material Classification

Design Coefficient and Design Stress
Sr Minimum Required Pipe Material Design Design Stress,
NO Strength (MRS) Classification Coefficient, σ = MRS/C
(Mpa) Number C (Mpa)
< 1.4 32
I 45.0 450
1.6 28
< 1.4 36
II 50.0 500
1.6 31

02
Manufacturing of PVC-O pipes involve process of controlled circumferential and axial
orientation of molecular structure resulting in formation of laminar structure of the
material used in the pipe construction.
4.1 Classification of pipes:

The pipes shall be classified by their pressure ratings (Nominal pressures) (PN) at
27oC and their material class classification and design coefficient as per following
Table No. 2
Table No. 2 Pressure Rating and Working Pressure of Pipes
Sr. Design
No. Coefficient, Pressure Rating (PN)
C
I - For Material Classification- Class 450
a) 1.4 PN 10 -- PN -- PN 16 -- PN 20 -- PN 25 --
12.5
b) 1.6 -- PN 10 -- PN -- PN 16 -- PN 20 -- PN 25
12.5
II - For Material Classification- Class 500
a) 1.4 -- PN -- PN 16 -- PN 20 -- PN 25 -- --
12.5
b) 1.6 PN 10 -- PN -- PN 16 -- PN 20 -- PN 25 --
12.5
Working pressure corresponding to various pressure ratings-
Pressure Ratings Working Pressure
PN 10 1.0 Mpa (10 kg/ cm2)
PN 12.5 1.25 Mpa (1.25 kg/ cm2)
PN 16 1.6 Mpa (16 kg/ cm2)
PN 20 2.0 Mpa (20 kg/ cm2)
PN 25 2.5 Mpa (25 kg/ cm2)

All PVC-O pipes in a single consignment of the same grade, same nominal pressure,
same size and manufactured under essentially similar conditions shall constitute a lot.
The number of test samples to be taken from a lot shall depend on the size of the lot,
outside diameter of the pipe and type of test as given in IS 16647.
5.1 Visual and Dimensional Requirement
 The number of test samples to be taken from a lot shall depend on the size of the
lot and the outside diameter of the pipes, and shall be in accordance with following
Table No.3

03
Table No. 3
Scale of Sampling for Visual Appearance, Colour and Dimensional Requirement
Sr. Number of Sample No. Sample Size Cumulative Acceptance Rejection
No. Pipes in a Lot Sample Size No. No.
(1) (2) (3) (4) (5) (6) (7)
I Upto 1000 First 13 13 0 2
Second 13 26 1 2
II 1000 to 3000 First 20 20 0 2
Second 20 40 1 2
III 3000 to 10000 First 32 32 0 3
Second 32 64 3 4
IV 10001 and First 50 50 1 4
above
Second 50 100 4 5
 These pipes shall be selected at random from the lot.

 The number of pipes given for the first sample in Col.4 of Table No. 3 shall
be taken from the lot and examined for visual appearance, colour and
dimensional requirement given in point 6 below. A pipe failing to satisfy any
of these requirement shall be considered as defective. The lot shall be
deemed to have satisfied these requirement, if the number of defective
found in the first sample is less than or equal to the corresponding
acceptance number given in Col no. 6 of Table No. 3. The lot shall be deemed
not to have met these requirements, if the number of defectives found in
the first sample is greater than or equal to the corresponding rejection
number given in Col.7 of Table No.3. If however the number of defectives
found in the first sample lies between the corresponding acceptance and
rejection number given in Col 6 and Col 7, a second sample of the size given
in Col. 4 shall be taken and examined for these requirements. The lot shall
be considered to have satisfied these requirements, if the number of
defectives found in the cumulative sample is less than or equal to the
corresponding acceptance number given in Col. 6, otherwise not.
5.2 Vicat Softening Test

 The lot having satisfied the requirement for visual appearance and colour
and dimensional requirement as per para 5.1, shall be tested for Vicat
softening temperature. The number of test samples to be taken from lot
shall be as per following Table No.4

04
Table No 4 Scale of Sampling for Vicat Softening Temperature and
Density Test.
Sr. Number of Sample Sample Cumulative Acceptance Rejection
No. Pipes in a Lot Number Size Sample Size Number Number
(1) (2) (3) (4) (5) (6) (7)
i) For nominal outside diameter (dn) up to and including 110 mm
First 5 5 0 2
a) Upto 1000
Second 5 10 1 2
b) 1001 to First 8 8 0 2
3000 Second 8 16 1 2
c) 3001 to First 13 13 0 2
10000 Second 13 26 1 2
d) 10001 and First 20 20 0 3
ii) For dn above 110 mm
First 3 3 0 2
a) Upto 3000
Second 3 6 1 2
b) 3001 to First 5 5 0 2
10000 Second 5 10 1 2
c) 10001 and First 8 8 0 2
 For this purpose, the number of pipes given for the first sample in Col No. 4 of
Table No.4 shall be taken from the lot. The sample pipe failing the Vicat
softening test shall be considered as defective. The lot shall be deemed to
have met the requirement given in this specification for the Vicat softening
test. If the number of defectives found in the first sample is less than or equal
to the corresponding acceptance number given in Col No. 6. The lot shall be
deemed not to have met these requirements, if the number of defectives
found in the first sample is greater than or equal to the corresponding
rejection number given in Col No.6. If, however, the number of defectives in
the first sample lies between the corresponding acceptance and rejection
numbers given in Col No.6 and Col. 7 a second sample of size given in Col No.4
shall be taken and examined for the requirement. The lot shall be considered
to have satisfied the requirement, if the number of defectives found in the
cumulative sample is less than or equal to the corresponding acceptance
number given in Col No.6 otherwise not.
5.3 Density
The lot having satisfied the requirement for visual appearance and colour and
dimensional requirement shall be tested for density. For this purpose,
procedure adopted for sampling and criteria for conformity shall be the same
as that given in above point No. 5.2 and Table No.4.

05
5.4 Resistance to External Blows at 0o C
The lot having been found satisfactory according to above para 5.1, 5.2 and 5.3
shall be tested for resistance to external blows at 0o C. For this purpose, the
procedure adopted for sampling and criteria for conformity shall be as per
following Table No. 5.
Table No 5 Scale of Sampling for Resistance to External Blows at 0°C

Sr No. Number of Sample Sample Cumulative Acceptance Rejection
Pipes in a Lot Number Size Sample Size Number Number
(1) (2) (3) (4) (5) (6) (7)
First 3 3 0 2
i) Upto 3000
Second 3 6 1 2
First 5 5 0 2
ii) 3001 to 10000
Second 5 10 1 2
10001 and First 8 8 0 2
iii)
NOTE – The numbers mentioned in col 4 to col 7 represent the number of times the test is to be
carried out and do not represent either the number of pipe samples or number of blows or
number of failures.
5.5 Ring Stiffness Test

The Lot having satisfied the requirements for visual appearance and colour and
dimensional requirements as per para 5.1 shall be tested for requirements of ring
stiffness. The number of pipes to be taken from the lot shall depend on the size of the
lot and shall be according to following Table No. 6. If the first sample drawn fails the
test, resampling should be done from the lot which has satisfied the dimensional and
visual requirements. The lot shall be considered to have met the requirements of
these lots, of none of these samples tested fails.
Table No 6 Scale of Sampling for Ring Stiffness Test

Sr. No. Number of Pipes in a Lot Sample Size for Sample Size for
Sizes Less than or Sizes Greater
Equal to 500 mm than 500 mm
i) Upto 1000 2 1
ii) 1001 to 3000 3 2
iii) 3001 and above 4 3

1. Dimensions : Outside diameter, Wall thickness, Length of pipe
3. Colour
4. Opacity
5. Resistance to hydrostatic pressure
06
6. Resistance to external blows at 00 c
7. Ring Stiffness
8. Orientation Factor
9. Physical and Chemical Characteristics
of Engineer-in-charge/WRD/QC/TPI.
6.1 Dimensions
6.1.1 Outside Diameter: The Nominal outside diameter, outside diameter at

any point and their tolerances shall be as given in following Table No.7
Table No 7 Outside Diameter and Tolerances

Sr. Nominal Outside Mean Outside Diameter, dem Outside Diameter at Any Point, dc
No. Diameter, dn
Min Max Min Max
i) 63 63.0 63.3 62.2 63.8
ii) 75 75.0 75.3 74.8 75.9
iii) 90 90.0 90.3 88.9 91.1
iv) 110 110.0 110.4 108.6 111.4
v) 125 125.0 125.4 123.5 126.5
vi) 140 140.0 140.5 138.3 141.7
vii) 160 160.0 160.5 158.0 162.0
viii) 180 180.0 180.6 177.8 182.2
ix) 200 200.0 200.6 197.6 202.4
x) 225 225.0 225.7 222.3 227.7
xi) 250 250.0 250.8 242.0 253.0
xii) 280 280.0 280.9 276.6 283.4
xiii) 315 315.0 316.0 311.2 318.8
xiv) 355 355.0 356.1 350.7 359.3
xv) 400 400.0 401.2 395.2 404.8
xvi) 450 450.0 451.4 444.6 455.4
xvii) 500 500.0 501.5 494.0 506.0
xviii) 560 560.0 561.7 553.2 560.8
xix) 630 630.0 631.9 622.4 637.6
xx) 710 710.0 712.0 701.4 718.6
xxi) 800 800.0 802.0 790.4 809.6
xxii) 900 900.0 902.0 889.2 910.8
xxiii) 1000 1000.0 1002.0 988.0 1012.0
xxiv) 1200 1200.0 1202.0 1185.6 1214.4
6.1.2 Wall Thickness: The wall thickness of the pipes shall confirm to values
specified in following Table No.8

07
Table No. 8 Wall thickness of the pipe
Wall Thickness, en (mm) for various pipe material classification and design stress coefficient (C)
Nominal
Sr. Diameter, dn Class 450/C = 1.4 Class 500/C = 1.4 Class 450/C = 1.6 Class 500/C = 1.6
No.
(mm)
Nominal Pressure, PN Nominal Pressure, PN Nominal Pressure, PN Nominal Pressure, PN
10 12.5 16 20 25 12.5 16 20 25 10 12.5 16 20 25 10 12.5 16 20 25

i) 63 1.1 1.3 1.7 2.1 2.6 1.2 1.5 1.8 2.3 1.2 1.5 1.8 2.3 2.9 1.1 1.3 1.7 2.1 2.6
ii) 75 1.3 1.6 2 2.4 3.1 1.4 1.8 2.2 2.7 1.4 1.8 2.2 2.7 3.4 1.3 1.6 2 2.4 3.1
iii) 90 1.5 1.9 2.4 2.9 3.7 1.7 2.1 2.6 3.3 1.7 2.1 2.6 3.3 4.1 1.5 1.9 2.4 2.9 3.7
iv) 110 1.8 2.3 2.9 3.6 4.5 2 2.6 3.2 4 2 2.6 3.2 4 5 1.8 2.3 2.9 3.6 4.3
v) 125 2.1 2.6 3.3 4 5.1 2.3 2.9 3.6 4.5 2.3 2.9 3.6 4.5 5.6 2.1 2.6 3.3 4 5.1
vi) 140 2.3 2.9 3.6 4.5 5.7 2.6 3.2 4 5.1 2.6 3.2 4 5.1 6.3 2.3 2.9 3.6 4.5 5.7
vii) 160 2.6 3.3 4.2 5.1 6.5 2.9 3.7 4.6 5.8 2.9 3.7 4.6 5.8 7.2 2.6 3.3 4.2 5.1 6.5
viii) 180 3 3.7 4.7 5.8 7.3 3.3 4.2 5.2 6.5 3.3 4.2 5.2 6.5 8.1 3 3.7 4.7 5.8 7.3
ix) 200 3.3 4.1 5.2 6.4 8.1 3.6 4.6 5.7 7.2 3.6 4.6 5.7 7.2 9 3.3 4.1 5.2 6.4 8.1
x) 225 3.7 4.6 5.8 7.2 9.1 4.1 5.2 6.4 8.1 4.1 5.2 6.4 8.1 10.1 3.7 4.6 5.8 7.2 9.1
xi) 250 4.3 5.1 6.5 8.6 10.2 4.5 5.8 7.2 9 4.5 5.8 7.2 9 11.2 4.1 5.1 6.5 8 10.2
xii) 280 4.6 5.7 7.2 9 11.4 5.1 6.4 8 10.1 5.1 6.4 8 10.1 12.5 4.6 5.7 7.2 9 11.4
xiii) 315 5.1 6.4 8.1 10.3 12.8 5.7 7.2 9 11.4 5.7 7.2 9 11.4 14.1 5.1 6.4 8.1 10.1 12.8
xiv) 355 5.8 7.2 9.2 11.4 14.4 6.4 8.2 10.1 12.8 6.4 8.2 10.1 12.8 15.9 5.8 7.2 9.2 11.4 14.4
xv) 400 6.5 8.1 10.3 12.8 16.2 7.2 9.2 11.4 14.4 7.2 9.2 11.4 14.4 17.9 6.5 8.1 10.3 12.8 16.2
xvi) 450 7.4 9.3 11.6 14.4 18.2 8.3 10.3 12.8 16.2 8.3 10.3 12.8 16.2 20.1 7.4 9.3 11.6 14.4 18.2
xvii) 500 8.2 10.9 12.9 16 20.3 9.2 11.4 14.2 18 9.2 11.4 14.2 18 22.3 8.2 10.4 12.9 16 20.3
xviii) 560 9.2 11.6 14.4 17 23.7 10.3 12.8 15.9 20.2 10.3 12.8 15.9 20.2 25 9.2 11.6 14.4 17.9 22.7
xix) 630 10.3 13 16.2 20.1 25.5 11.6 14.4 17.9 22.7 11.6 14.4 17.9 22.7 28.1 10.3 13 16.2 20.1 25.5
xx) 710 11.6 14.7 18.3 22.7 28.7 13.1 16.2 20.2 25.6 13.1 16.2 20.2 25.6 31.7 11.6 14.7 18.3 22.7 28.7
xxi) 800 13.1 16.5 20.6 25.5 32.4 14.7 18.3 22.7 28.8 14.7 18.3 22.7 28.8 35.7 13.1 16.5 20.6 25.5 32.4
xxii) 900 14.7 18.6 23.1 28.7 36.4 16.5 20.8 25.5 32.4 16.5 20.6 25.5 32.4 40.2 14.7 18.6 23.1 28.7 36.4
xxiii) 1000 16.4 20.7 25.5 31.9 40.5 18.4 22.8 28.4 36 18.4 22.8 28.4 36 44.6 16.4 20.7 25.7 36.9 40.5
xxiv) 1200 19.6 24.8 30.8 38.3 48.5 22 27.4 34 40.2 22 27.4 34 43.2 53.5 19.6 24.8 30.8 38.3 48.5
D:\POOJA\HANDBOOK FINAL\HANDBOOK VOLUME II\10 O-PVC SPECIFICATIONS print copy.docx 08

6.1.3 Length: The pipe shall be supplied with the length not less than the declared
nominal pipe length. It is recommended that the nominal pipe length to be
supplied may be 6m, 10m and 12m. The pipes may be supplied in other
lengths where so agreed upon between the manufacturer and the purchaser.

When checked without magnification glass, the internal and external surfaces
of the pipe shall be smooth, clean and free from scoring, cavities and other
surface defects. Slight shallow longitudinal grooves or irregularities in the pipe
shall be permissible provided the wall thickness remains within the
permissible limits. The material shall not contain visible impurities. The ends
of the pipe shall be either cut cleanly and reasonably square to the axis of the
pipe or chamfered at the plain end at approximately 15o to the axis of the
pipe.
6.3 Colour
The colour of the pipe shall be any shade of grey, blue or cream. The pipe may
also be supplied in any other colour as agreed to between the manufacturer
and the supplier. Slight variations in the appearance of the colour may be
permitted.
6.4 Opacity
The wall of the pipe shall not transmit more than 0.2 % of the visible light
falling on it when tested in accordance with IS 12235
6.5 Resistance to hydrostatic pressure

Resistance to hydrostatic pressure shall be verified using the induced stresses
derived from the analysis of the test data in accordance with IS 16462. For a
period of 10 h at 270 C and 1000 h at 270 C, the 99.5 percent LPL value shall be
taken as the minimum stress level.
For a period of 1000 h at 600 C, the 99.5 percent LPL value established from
analysis of test data at 600 C in accordance with IS 16462 can be taken as the
minimum stress level. In case of lack of data, alternatively, a value of 0.625
times the MRS (Minimum Required Strength) value shall be taken as the
minimum stress level.
When tested in accordance with IS 12235, the pipe shall not fail in less than
the times stated above. The test shall be carried out not earlier than 24 h after
the pipes have been manufactured.
6.6 Resistance to external blows at 00 C
Pipes when tested at 00 C in accordance with IS 12235 using striker mass as
given in Col 3 of following Table No. 9 and drop height for various nominal sizes
as per Col 4 of Table No. 9, shall have a true impact rate (TIR) of not more than
10 percent. In case of socket ended pipes, this test shall be carried out on the

09
plain portion of the pipes taken atleast 100mm away from the route of the
socket.
Table No 9 Classified Striker Mass and Drop Height Conditions for the
Falling Weight Impact Test
Sr. Nominal Diameter, dn Total Mass Drop Height
No. (mm) (kg) (mm)
i) 63 4 2.0
ii) 75 5 2.0
iii) 90 5 2.0
iv) 110 6.3 2.0
v) 125 6.3 2.0
vi) 140 8 2.0
vii) 160 8 2.0
viii) 180 10 2.0
ix) 200 10 2.0
x) ≥ 225 12.5 2.0
NOTE - Impact characteristics can change over time. These values are applicable only
at the time of manufacture.
6.7 Ring Stiffness

The minimum value of ring stiffness of pipe when determined in accordance
with IS 12235 shall be as specified in following Table No. 10
Table No. 10 Ring Stiffness of Pipes.

Sr. No. Nominal Diameter, dn Ring Stiffness Ring Stiffness
(For Specific Jointing Techniques)
(mm) (KN/m2) (KN/m2)
(1) (2) (3) (4)
i) 63 ≥ 20
ii) 75 ≥6 ≥ 12
iii) 90 ≥ 10
iv) 110 ≥ 10
v) 125 ≥8
vi) 140 ≥4 ≥7
vii) 160 ≥7
viii) ≥ 200 ≥6
 Pipes of stiffness less than 4 KN/m2 might not be suitable where high vacuum or external
pressure could be developed and could need special installation techniques where
installed below ground.
 Due to specific jointing techniques in water supply and installation below ground, higher
stiffness may be needed.
6.8 Orientation Factor

The determination of the stretch ratios (axial orientation factor and
circumferential factor) shall be carried out as per procedure mentioned in
Annexure-E of IS 16647.

010
6.9 Physical and Chemical Characteristics
When tested in accordance with the methods as specified in following Table No. 11
using the parameters indicated therein, the pipe shall have Physical and Chemical
Characteristics conforming to the requirement given in following Table No. 11
Table No 11 Physical and Chemical Characteristics.

Sr. Characteristic Requirement Test Parameters Test Method, Ref in
No.
(1) (2) (3) (4) (5)
i) Vicat Softening ≥ 80°C Shall confirm to IS 12235 IS 12235 (Part 2)
temperature (Part 2) and
Number of test pieces = 3
ii) Effect on water As per IS 4985 IS 12235 (Part 4) and IS 12235 IS 12235 (Part 4) and
(Part 10) IS 12235 (Part 10)
iii) Resistance to Di- No attack at any part of Temperature of bath- 15°C IS 12235 (Part 11)
chloromethane at a the surface of the test ±5°C
specific temperature piece Immersion time- 15 min and
(Degree of gelation) minimum wall thickness – 1.5
mm
iv) Alternative test to Minimum stress 48 In accordance with IS 12235 IS 12235 (Part 13)
resistance to di- MPa (Part 13)
chloromethane test
Uni-axial tensile test

Each pipe shall be indelibly marked in English language at intervals of not
more than 1 m . The marking shall show the following.
2. Pipe material and material classification Number
3. Outside diameter
4. Nominal pressure
be inscribed.

As PVC-O pipes are durable and light, they are more likely to be mishandled.
 When transporting pipes, flat bed vehicles should be used. The bed should be
free from nails and other projections. When practical, pipes should rest
uniformly on the vehicle over the whole length.

011
 The vehicles should have side supports approximately 2 m apart and the pipes
should be secured effectively during transport. All posts should be flat with no
sharp edges.
 When loading spigot and socket pipes, the pipes should be stacked on the
vehicle so that the socket do not take excessive loads.
 Where pipes overhang the vehicle, the amount of overhang should not exceed
1 m.
 High stiffness pipes should be placed at the bottom of the load and low
stiffness pipes at the top.
 Care should be taken to avoid positioning the pipes near to any exhaust
systems or any other potential hazards such as diesel oil, paints or solvents.
 When pipes are transported in bundles, the bundles should be secured
effectively and off- loaded with due care.
 Mechanical lifting equipment used for lifting pipes and pipe bundles should
not damage the pipe. Fork-lift forks should be flat and protected. Cranes
should have spreader bars. No wire ropes, chains or hooks should be used.
Slings should be made of rope or webbing 7 to 10 cm wide.
 If pipes have been telescoped for transporting, the inner pipes should be
removed first and stacked separately.
9.0 Stacking of Pipes

Following precautions shall be taken so as to eliminate potential damage to pipes
 Store the pipes horizontally on a flat surface and place supports every 1.5 m
to avoid the bending of the pipe.
 Avoid scratches especially in the crest of the socket, due to dragging the pipe
on the ground, mainly if the surface is made of stone, concrete or asphalt.
 Do not stack pipes more than 1.5 m height, as this can damage lower pipes or
even the upper pipes can fall.
 The sockets should be free, alternating sockets and ends.
 In case of prolonged sun exposure, protect pallets with an opaque material.
White colour is preferable because it avoids the over heating of pipes.
10.0 Valves
pipeline at various locations.
10.1 Air Valve :
three areas: firstly, in the water filled stage of the pipeline, filled with water by a
012
10.2 Scour Valve :
These Valves are generally provided to drainout the pipeline.The exact location
or drain, it cannot be completely drained into the channel. In such a situation it is
better to locate a scour connection at the lowest point that will drain by gravity
A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve

charge shall be conducted on random samples of pipes collected from site.
These test shall be as per those given in forgoing para No.6.0


013
12.2 Demarcation
curves, in the beginning. The final line out will be done by fixing reference stone
at suitable distances on either side of the center line, beyond the canal edges
so that they are not disturbed during the construction period. The position of
these stones will be marked on the cross section.

Engineer-In-charge.
3. Levels 2 Nos.
4. Staves 4 Nos.

014
than 500 mm.
015

While laying of PVC-O pipes, all precautions as mentioned in IS 7634 (Part-
3) shall be taken.
 The trench bottom shall be constructed to provide a firm, stable and uniform
support for the full length of the pipeline. There should be no sharp objects
that may cause point loading.
 A minimum bedding thickness of 100 to 150 mm under the pipe shall be
provided by watering and compaction
 For pipes of diameter 100 mm or greater, bell holes in the bedding , under
each socket joint, shall be provided by removing some of the bedding
material, to accommodate the larger diameter of the joint and to permit the
joint to be made properly.
 The pipes shall be preferably laid with the spigots entered into the sockets in
the same direction as the intended flow of water.
 To sustain thrust caused by internal pressure, concrete anchor blocks should
be provided at all changes of direction, tees, blank ends, large reductions in
diameter and valves.
 Metal marker tape can be laid into the final backfill to enable electronic
location of the pipe line, if required.
15.1 Jointing of pipes shall be carried out as per following procedure.

 Lubricate the chamfer of the spigot and the seal with joint lubricant.
 Line up the pipe as much as possible horizontal and vertically.
 Insert only the chamfer edge of the socket, just to support the pipe but
leaving the socket lip free.
 In case of pipes with nominal daimeter ≤ 250 mm, a firm and dry push
should be given to seize the momentum produced by the free
movement in the lip of the socket and introduce it until the mark is
hidden into the socket.
 When installing pipes with diameters > 250 mm, one should use mechanical
means to introduce the pipe using materials such as woods, hoists, tackles or
slings.

016
15.2 The joint shall fulfill the following criteria
15.2.1 Short-Term Pressure Test for Leak Tightness of Assemblies
When an assembly with one or more elastomeric sealing ring type joints is
tested using a hydrostatic pressure and angular deflection in accordance with IS
12235 and the test conditions given in following Table No.12, the assembly shall
conform to the requirement given in Table No.12.
Table No 12 Test Conditions and Requirements for Short-Term Assembly Test.
Sr. Test Temperature °C Test Pressure Test Time Test
No. (MPa) (min) requirement
No leakage at
Pressure calculated in any point of the
T±2 One cycle in
accordance with fig.2 jointing areas
i) (where T is any temperature accordance with fig.2
and para 11.2.2 of IS throughout the
between 20°C and 27°C) of IS 16647
16647 whole test
cycle
NOTE - The pressure changes from one pressure level to the next shall take place within the periods
indicated, but need not take place at strictly linear rates.
15.2.2 Short-Term Negative Pressure Test for Leak Tightness of Assemblies

When an assembly with one or more elastomeric sealing ring type joints is
tested using negative pressure with angular deflection and deformation in
accordance with IS 12235 and the test conditions given in following Table No.13,
the assembly shall conform to the requirement given in Table No.13. Procedure
for calculating negative pressure capability of pipes for different class and
design coefficient is as given in Annex 1 of IS 16647.
Table No 13 Test conditions and Requirements for Short-Term Negative-
Pressure Assembly Test.
Sr. Test Test Pressure Test Time Test requirement
No. Temperature °C (MPa) (min)
i) The change in
negative pressure
T±2
shall be not more
(where T is any Pressure calculated in
One cycle in accordance than 0.005 MPa
temperature accordance with fig.3 of
with fig.3 of IS 16647 during each 15
between 20°C IS 16647
min test period
and 27°C)
shown in fig.3 of IS
16647
NOTES –
1. The pressure change from one pressure level to the next, need not take place at strictly linear
rates.
2. For pipes with integral sockets, there is no need for testing with angular deflection.
3. For pipes of ring stiffness less than 4 KN/m 2, it is allowed to support the pipe to avoid collapsing
during testing.

017
15.2.3 Long-Term Negative Pressure Test for Leak Tightness of Assemblies
When an assembly with one or more joints selected from elastomeric sealing
ring type sockets and other end-loaded-bearing and non-end-load- bearing
joints for oriented PVC-U components for a piping system is tested in
accordance with IS 12235 using the test conditions given in following Table No.
14 for the test temperatures of 27o C and 40o C, the assembly shall conform to
the requirements given in Table No. 14
Table No. 14 Test Requirements for Long-Term Pressure Testing of Assembled
Joints.
Sr. No. Test Test Pressure Test Time Test requirement
Temperature (MPa) (hr)
°C
i) 27 1.3 PN 1000 No leakage at any

point of the jointing
areas at least for the
ii) 40 1.1 PN 1000 test time
Note : The PN rating to be taken to calculate the test pressure shall be the PN rating of the fitting
and if pipe with an integral joint is being tested, it shall be the PN rating of the pipe.
15.2.4 Elastomeric Seals

Elastomeric Seals used for jointing components shall conform to both the
following requirements.
 Rings shall conform to the material requirements specified in IS 5382
 Rings shall be free from chemical agents such as plasticizers that could
have a detrimental effect on the pipes or fitting or on the quality of the
water.
16.0 Field Testing of Pipeline system.
16.1 General
All pipelines should be tested before being brought into service. The test should
be a hydrostatic test performed by filling the pipeline with water and raising the
pressure to the selected test pressure and maintaining this for a sufficient period
to allow for absorption of water by the pipe material.
The test should confirm to following conditions
a) be carried out at ambient temperature;
b) be applied for at least 1 h, but not more than 24 h; and
c) not exceed 1.5 times the maximum rated pressure of the lowest rated
component.

018
16.3 Test Procedure
 Pipe systems should be hydraulically tested in lengths appropriate to the

diameters and site conditions. Pipelines longer than 800 m may require testing
in sections. Preferably, the length selected for test is between 300 m and 500 m.
 Testing should not take place until any concrete used for anchoring has fully
cured (normally 72 h) and attained its required strength. Solvent cemented joints
must be allowed to harden for a minimum of 24 h before being subjected to test
conditions.
 It is important to provide sufficient backfill over the main barrel of the pipe, to
prevent displacement and to maintain stable temperature conditions. Leave
joints free for inspection.
 The test position should be located at the lowest point of the pipeline profile to
encourage expulsion of air as the pipe is being filled with water. Adequate air
release mechanisms should be located at all high points along the line.
 Before filling the pipeline, all line valves and air venting systems should be
checked open. All air must be removed from the system.
 Fill the system slowly. Water velocity must not exceed 0.6 m/s. Potable water
pipelines should be tested with potable water only. After charging, close all air
valves and check proper action of automatic valves.
 Allow the system to stabilize under a nominal pressure for a minimum of 2 hours.
Apply pressure steadily. Observe pressure gauges throughout and record the
rates of pressure increase.
 The pressure should be increased till the specified pressure is reached at the
lowest part of the section. Maintain test pressure at this level, by additional
pumping if necessary, for a period of 1 hour.
 Close all valves and disconnect the pressurizing unit. No further water should be
allowed to enter the system for a further period of 1 hour.
 During the test period, carry out a visual examination of all joints and exposed
connections.
16.4 Leak Detection

 There should be no leakage in any part of the section.
 If there has been a decrease in pressure during this period other than due to
leakage, the original pressure is re-established by injecting a measured quantity
of water into the section.
 The test is considered to be satisfactory if
a) there is no decrease in pressure (a slight rise in pressure is also, possible due
to changes in ambient temperatures),
b) the measured quantity of water required to reinstate the pressure to the
original test pressure is less than the ‘permissible maximum’ Q,
Where,
Q = 4.5 liters per 1.6 km per 25 mm of nominal bore per 30 m head of test pressure
per 24 hours.
019
 On completion of any test, the residual pressure should be released slowly and in
a carefully controlled manner.
 All defects revealed in the test should be rectified and the procedure repeated
until a satisfactory result is obtained.
 If any leakage is found during testing of pipeline, Contractor will have to attend
the same immediately and rectify at his cost . If Contractor fails to rectify the
defect, the entire length of pipeline between two adjacent outlets shall be
rejected. If any intermediate payment is made to the Contractor for portion under
rejection, the same shall be recovered from the outstanding dues of the
Contractor.
the material, shall be subject to approval by the Engineer-in-Charge.
(b) The backfill material shall be placed to the line and grades as shown
on drawings or as prescribed in this paragraph or as directed by the
Engineer-in-Charge.
up as uniformly as practicable on both sides of pipe to prevent unequal
loading.
cured. The size and weight of equipment will depend on nature of material,
the height and load assumed in design of structure. The backfill close to the
using pneumatic / hand tampers as appropriate for dry density at average bulk
density (+/- 10%). The moisture content of the earth fill placed against the rock
or the structure shall be on higher/lower side of OMC by about 2% or so, to
allow it to be compacted. Profuse watering shall be done to pervious materials
(sand) before compaction as per instruction of the Engineer-in-Charge.
Compaction at junction of earthwork and backfill around the structure shall
be carried out with special care.

020
(15x15x45)CM embedded in concrete block of size (30x30x30)CM. The base
reference.
2 R.I.T.E.S. (Rail India Technical Economics Services)Mumbai
3 S.G.S, Mumbai
5 VJTI, Mumbai
021
6 CWPRS(Central Water & Power Research Station), Pune

latest editions of relevant IS Codes and determined by the Engineer In-charge.
The day-to-day and periodical tests to be carried out on materials mixes and
placed concrete, mortar etc. shall be specified by the Engineer In-charge from
time to time and the Contractor shall provide free of cost all facilities towards
collections of samples etc. unless otherwise specified. Labours for collecting
samples and transportation of the samples to quality control authorities for
test shall be provided free of cost by the contractor. Also electricity, fuel,
water curing tank and stores etc shall be provided free of cost by the
contractors.
(b) The materials shall be tested in QC laboratory or at any other place directed by
the Engineer In-charge. The Contractor shall obtain the test results from the
concern authority and the results given by such authorities shall be considered
to determine whether all materials, workmanship are of respective standard
described in contract and in accordance with the instructions of the Engineer
In-charge. The Contractor’s representatives shall, however, be given access to
all operations and tests that may be carried out as aforesaid so that he may
satisfy himself regarding the procedure and methods adopted. It shall then be
the Contractor’s responsibility to produce on the work, materials and finished
item to the standard as determined by the laboratory tests or to take follow up
action to rectify the quality.
(c) Testing charges for testing of Cement, TMT bars, all types of pipes and specials
including cost of samples and its collection shall be borne by the Contractor.
present at site at the time of taking samples or fail to provide required labours
and other equipment to collect the samples, the same shall be taken by the
Engineer In-charge, and the samples selected shall be considered as authentic.
The cost incurred by the Engineer-In-charge when the Contractor fails to
provide required men and materials for collecting samples and or their
transport shall be recovered from the Contractor.


022
Engineer in charge.

generation work)
Two to Four
(As per work)
(One for each L.A.)

Slump, Cube Moulds&CTM
20.4 It is the responsibility of the contractor to assure the desired qualityof work.
Whenever the testing of construction materials, pipes are required as per the
detailed specifications or otherwise required by the Engineer-in-Charge,the
same shall be carried out at the laboratory, selected by the Engineer-in-
Charge at Contractor’s cost. The other tests of mortar,concrete,sand, coarse
aggregates etc.shall be carried out in field laboratory set up by the contractor
in presence of quality control representative at contractors cost. Contractor
shall through this procedure assure the quality of work.
20.5 The materials,mixes and any other rrangements,including labours,shall be
supplied by the contractor.The samples fo testing shall be taken in the
laboratories,to get himself satisfied about procedures of testing etc. Even if
the contractor or his representative fails to remain present while collecting
samples or testing,the results will be considered as authentic and binding on
the contractor.
023
contractor.
from any damages.
charge shall verify and endorse the location of the marking and handover
at his own cost.

024
22.1 Measurement
22.2 Payment

----------***----------

025

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Government of Maharashtra

Water Resources Department

HANDBOOK FOR PIPE DISTRIBUTION

NETWORK FOR IRRIGATION

2 Applicable IS 1 1 1-2 1-2 1 1-2 1-2 1 1-2 1

4 Manufacturin 3-5 2 2-3 3-4 3 3-4 3-5 2-6 2-3

9 Stacking of 14 9-10 12 8 9 9 12 14-15 9 12

Water Resources Department

SPECIFICATION FOR HIGH

2.0 Applicable IS Codes, ISO Codes

g) The addition of not more than 10 % of the manufacturer's own rework

Pipe Manufacturing Procedure

b) Pipe shall be classified by pressure rating (PN) corresponding to the

Table No. 2 : Pressure Ratings (Reproduced from IS 4984)

d) Pipes shall be designated according to the grade of material followed by

4.3.1 Types of Injection Moulded / Machined HDPE Fittings

4.3.2 Types of Fabricated HDPE Fittings

5.0 Sampling criteria for Selection of Pipe for Testing Purpose

5.1 Dimensional and Visual Requirements

Table No.3 Scale of Sampling for Visual and Dimensional Requirements

Table No.4. Scale of Sampling for Tests for Hydraulic Characteristics,

No. of Pipes Sample Size

6.0 Pre Delivery Testing of Pipes

These test shall be carried out by the contractor in the presence of

6.1.1 Outside Diameter:

1) Outside diameter of the pipe shall be taken as the average of two

2) Ovality shall be measured as the difference between maximum outside

Table 8. Wall thickness of pipes for material grade PE 100.

6.1.3 Length of straight pipe:

6.2 Visual Appearance

6.3 Internal Pressure Creep Rupture Test:

6.7 Melt Flow Rate (MFR)

6.8 Carbon Black Content & Dispersion

7.0 Marking on Pipes

8.0 Transportation of Pipe:

Following precaution shall be taken during transportation of pipes

9.0 Stacking of Pipes at Site

10.1 Air Valve :

10.2 Scour Valve :

10.3 Control Valve :

11.0 Post-delivery testing of pipes

12.0 Site Preparation

1. Total station and its accessories 1 set

13.0 Excavation for Pipe Trenches

14.0 Laying of Pipes

15.1 Fusion Welded Joints

15.5 Spigot and Socket Joint

16.0 Field Testing Of Pipeline System

The following procedure needs to be followed for HDPE pipe testing

17.0 Backfilling of Pipe Trenches

18.0 Permanent markings of Pipe alignment

19.0 Third Party Inspection

19.2 Testing of materials

20.0 Quality Control and Quality assurance

21.0 Operation, Maintenance and Handing over of the System

A certificate regarding smooth working of pipe distribution network from the

2.0 Applicable IS Codes

IS - 4985 Unplastisized PVC pipes for potable water supplies.