AFFORDABLE HOUSING DEVELOPMENT

INFRASTRUCTURE UTILITIES SPECIFICATIONS

PART 03 POTABLE WATER NETWOK

3.02 PIPES AND FITTINGS MATERIALS

3.02.01 Medium and High Density Polyethylene Pipes And Fittings

1. Applicable Standards

EN ISO 527 ................ Plastics -- Determination of tensile

properties
EN ISO 1133-1 ........... Plastics. Determination of the melt mass-
flow rate (MFR) and melt volume-flow rate (MVR) of
thermoplastics.
EN 1519 ..................... Plastic piping systems for soil and waste
discharge (low and high temperature) within the building structure
Polyethylene (PE)
EN ISO 1167 .............. Thermoplastic pipes, fittings and
assemblies for the conveyance of fluids Determination of the
resistance to internal pressure
EN ISO 1183-2 ........... Plastics Methods for determining the
density of non-cellular plastics Part 2: Density gradient column
method
EN ISO 2505 .............. Thermoplastics pipes Longitudinal
reversion Test method and parameters
EN ISO 3126 .............. Plastics piping systems Plastic
components Determination of dimensions
EN ISO 6259 .............. Thermoplastic pipes - Determination of
tensile properties
EN ISO 9080 .............. Plastic piping and ducting systems
determination of the long term hydrostatic strength of
thermoplastics materials in pipe form by extrapolation
EN 12099 ................... Plastics piping systems Polyethylene
piping materials and components Determination of volatile
content
EN ISO 12162 ............ Thermoplastic materials for pipes and
fittings for pressure applications - Classification and designation
Overall service (design) coefficient
2. Manufacture

a. MDPE and HDPE (PE) pipes and fittings shall be

manufactured from virgin materials only. Recycled, re-ground
or re-generated materials shall not be used.
b. HDPE pressure pipes and fittings shall be manufactured from
material conforming to polymer classification PE100 having a
minimum required strength value (MRS) of 10 MPa at 50 years
and 20C in accordance with ISO 4427. Design stress shall be

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8 MPa. The pipe manufacturer shall identify the manufacturer

of the resin, the resin type and classification.
c. The HDPE pipe material shall be certified as meeting the
requirements of the PE100+ Association.
d. HDPE pipes to be installed using trenchless technology
applications shall be manufactured from a PE100-RC material.
Pipes manufactured from such material shall have undergone
the Notched Pipe Test at an independent 3rd party laboratory
in accordance with ISO 13479 and the time to failure shall
have been a minimum of 8,760 hours (1 year). All other
characteristics shall comply with the PE100 requirements of
ISO 4427 and this specification.
e. HDPE pipes shall have a standard dimension ratio (SDR) of 11
unless indicated otherwise by the Engineer and shall have a
pressure rating of 16 bar (PN16) at 20C (de-rated to 11.8 bar
at 40C, in accordance with Annex A of ISO 4427 Part 1)
unless indicated otherwise by the Engineer.
f. Pipes and fittings shall be designed to achieve a minimum
working life of 50 years under all applicable loads,
environmental and installation conditions.
g. MDPE pressure pipes and fittings shall be manufactured from
material conforming to polymer classification PE80 having a
minimum required strength value (MRS) of 8 MPa at 50 years
and 20C in accordance with ISO 4427. Design stress shall be
6.4 MPa. The pipe manufacturer shall identify the
manufacturer of the resin, the resin type and classification.
h. MDPE pipes shall have a standard dimension ratio (SDR) of
11 unless indicated otherwise by the Engineer and shall have
a pressure rating of 12.8 bar (PN12.8) at 20C (de-rated to 9.5
bar at 40C, in accordance with Annex A of ISO 4427 Part 1)
unless indicated otherwise by the Engineer.
i. Pipes and fittings shall be homogeneous throughout and free
of visible cracks, holes, foreign inclusions, voids and other
injurious defects.
j. The resin from which the pipes and fittings are manufactured
shall comply with the requirements of ISO 4427 Part 1 and be
protected from UV attack by the addition of carbon black in
accordance with the standard.
k. Straight lengths of PE pipe shall be supplied in standard
lengths of 12m (-0/+50 mm) measured at 23C 2C. Unless
otherwise specified, coil length shall not exceed 100m. Coiled
pipes shall be coiled such that localised deformation is avoided
and the minimum internal diameter of the coil shall not be less
than 20 x outside diameter. Prior to jointing the degree of pipe
ovality shall not exceed the permissible levels given in Table 1
of ISO 4427, Part 2 and the Contractor shall, if required, use
mechanical re-rounding equipment to meet these
requirements. Field cut lengths of pipe used as closures may
not be shorter than 0.75 metre in length and shall be approved
by the Engineer.

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l. All pipes shall be indelibly marked at intervals of maximum 1m.

The colour of the pipe marking shall always contrast with the
colour of the pipe. Markings shall include the following
information:
i. Manufacturers name, trademark
ii. Material and designation i.e. PE100
iii. The nominal pressure (PN) of the pipe / fitting
iv. Dimension of the pipe (nominal outside diameter x
nominal wall thickness)
v. Standard Dimension Ratio (SDR)
vi. (f) Production period (date / batch code)
vii. (g) International Standard to which the pipe / fitting has
been produced to
viii. (h) Designation of the medium for which the pipe is
produced for (water, gas, sewage)
ix. (i) Stencilled in legible letters the pipe identification
number on the outside at each end. Ensure that the
same number appears on all record sheets and
documents relating to the manufacture, delivery and
testing of that pipe.
m. Pipes shall be delivered in wooden frames or similar
arrangement to avoid movement between pipes. Pipes shall
not be stacked higher than 1m in each frame or packing
arrangement.
3. Fittings

a. The butt fusion welding machine shall able to offer full

traceability for each welded joint identifying not only the
operator responsible for the joint but also technical data related
to that joint
b. Unless otherwise specifically approved by the Engineer, all PE
pressure pipe fittings for use with pipes of up to 355 mm OD
shall be injection moulded with the same polymer
classification, material type and pressure rating as the pipe to
which they are to be connected. All joints between PE pipes
and fittings shall whenever possible be by thermal butt fusion
welding or electro-fusion welding process.
c. Connections of PE pipes and fittings to metallic fittings shall be
made with PN16 backing rings with a stainless steel stiffener
insert or as recommended by the pipe or fitting manufacturer
and approved by the Engineer.
d. Transition fittings used to join the pipe to flanged fittings and
pipes made of other materials shall be certified by an
independent third party as being fully compliant with the Type
1 or Type 2 requirement of WIS 4-24-01 i.e. they shall prevent
the pull out of the pipe at their rated operational and test
pressures.

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e. Metallic fittings shall be fully coated to provide protection

against corrosion. The coating shall be a factory applied fusion
bonded epoxy or a nylon 11 based polyamide coating system,
have a minimum dry film thickness of 250 microns and comply
with the requirements of either AWWA C224 or WIS 4-52-01.
Any bolts, studs or nuts shall be of stainless steel (grade 304
or better) or else be protected with a coating that complies with
the requirements of WIS 4-53-03. All buried metallic fittings
shall be protected by petroleum impregnated primer, paste and
tape prior to back filling.
f. Where their use is approved by the Engineer, all compression
fittings shall be certified by an independent third party as being
fully compliant with the requirements of ISO 14236. They shall
be tested and certified as being class 1 end load bearing
fittings i.e. they shall prevent the pull out of the pipe at their
rated operational pressure. Only materials listed in Tables 1
and 2 of ISO 14236 shall be used in the manufacture of the
fitting body.
g. Where the use of fabricated fittings has been specifically
approved by the Engineer such fittings shall be designed and
manufactured in accordance with the requirements of ISO
4427, Part 3, in particular Annex B. The pressure derating
factors to be employed by the fittings fabricator shall be in
accordance with annex sections B3 and B5 unless they can
demonstrate that higher factors can be applied. The use of any
higher factors shall be approved by the Engineer prior to
commencement of fitting fabrication.
h. All PE fittings shall, as a minimum, be indelibly marked with the
following information:
i. Manufacturers name, trademark
ii. International Standard to which the pipe / fitting has
been produced to
iii. Material and designation i.e. PE100
iv. The nominal pressure (PN) of the pipe / fitting
v. Outside diameter and Standard Dimension Ratio (SDR)
vi. Production period (date / batch code)
i. PE Fittings shall be individually packed in bulk, bag or
individual protection against contamination. Electrofusion
fittings shall always be packed in a sealed bag or container.
The packaging shall, as a minimum, be labelled with the
manufacturers name, quantity, type and dimension.
4. Pipes and Fittings for Gravity Applications

a. Pipes and fittings for drainage applications shall be suitable for

carrying potable water, treated sewage effluent, raw sewage
and surface water at temperatures up to 40C as dictated by
the particular application and they shall comply with the
requirements of EN1519 or EN 12666, as appropriate.

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5. Testing of MDPE and HDPE Pressure Pipes and Fittings

a. The raw material and pipe manufacturers shall document and

certify all products and shall undertake all testing required by
ISO 4427 and this specification.

b. Prior to delivery of any pipes or fittings the pipe manufacturer

shall provide the Engineer with a comprehensive Inspection
and Testing Plan (ITP) for their approval. The ITP shall detail
all the certificates and documents that shall be provided by the
pipe manufacturer, together with details of the testing that they
shall undertake, its frequency and associated test reports.
Where the pipe manufacturer cannot themselves undertake
the required testing they shall employ an independent third
party laboratory to undertake the testing on their behalf.

c. Definition of material, pipe and fittings batches for the

purposes of batch release testing:

i. A raw material batch shall be considered as a batch of

material supplied by the resin producer having an
individual identification number or code. For the
purposes of this specification it shall also be the raw
material used to manufacture a particular pipe batch.

ii. A pipe batch shall be considered as a continuous

production run of a particular pipe OD and wall
thickness manufactured from one resin type with no
change in the manufacturing process.

iii. A batch of fabricated fittings shall be considered as

group of fittings of the same OD and wall thickness.

d. The pipe manufacturer shall undertake the following minimum

batch release testing.

Table 1 Release tests to be undertaken on each raw material batch

Sampling No. of Tests or

Characteristics Reference
Frequency Inspections

Compound Density ISO 4427-1 Section 4 Once per raw 1

material batch

Oxidation induction time ISO 4427-1 Section 4 Once per raw 1

material batch

Melt mass-flow rate ISO 4427-1 Section 4 Once per raw 1

material batch

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Table 2 Release inspections and tests to be undertaken on each batch of pipes

Sampling No. of Tests or

Characteristics Reference
Frequency Inspections

Appearance and colour ISO 4427-2 Section 5 Contuniously -

Geometrical ISO 4427-2 Section 6 Contuniously -

Marking This specification Each pipe or coil 1

Melt mass-flow rate ISO 4427-2 Section 8 Once per pipe batch 1

Elongation at break ISO 4427-2 Section 8 Once per pipe batch 1

Tensile strength at yield ISO 6259 (Tensile Once per pipe batch 1
on a sample cut from strength to be 19
HDPE pipe MPa)

Tensile strength at yield ISO 6259 (Tensile Once per pipe batch 1
on a sample cut from strength to be 15
MDPE pipe MPa)

Longitudinal reversion ISO 4427-2 Section 8 Once per pipe batch 1

Pipe wall thickness shall be measured and controlled on a continuous basis using and
ultrasonic thickness gauge or similar device that shall be regularly calibrated in accordance
with the gauge manufacturers recommendations.

e. In accordance with the recommendations of ASTM D 638, the

maximum thickness of the tensile strength test samples cut
from the pipe wall shall be 14 mm. In the event of the pipe wall
being thicker than 14 mm the pipe manufacturer shall machine
the test samples in accordance with the Table 3.
Table 3 Preperation of samples for tensile testing
Pipe Wall Thickness (WT) Test Sample Thickness No. of samples to be
(mm) (mm) taken from the pipe wall

14 WT 1

14 < WT 28 WT/2 2

28 < WT 42 WT/3 3

42 < WT 56 WT/4 4

56 < WT 72 WT/5 5

All testing shall be undertaken in accordance with ISO 6259 and all HDPE samples shall
achieve a minimum tensile strength at yield of 19 MPa in order for the pipe to successfully

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pass the test. MDPE samples shall have achieved minimum tensile yield strength at yield of
15 MPa.

Table 4 Release inspections and tests to be undertaken on each batch of fabricated fittings
Sampling No. of Tests or
Characteristics Reference
Frequency Inspections

Appearance and colour ISO 4427-2 Section Contuniously -

5

Geometrical ISO 4427-2 Section Contuniously -

6

Marking This specification Each fitting 1

Hydrostatic strength at 20oC, ISO 4427-3 Annex B Once per batch of 1 piece only
100hrs & 12.4MPa x HDPE fittings

Hydrostatic strength at 20oC, ISO 4427-3 Annex B Once per batch of 1 piece only
100hrs & 10 MPa x MDPE fittings

The fabricated fitting to be hydrostatically tested shall be a tee or branch provided the batch
in question contains this type of fitting, otherwise a bend shall be tested.
f. In the case of injection moulded fittings the manufacturer shall
issue a certificate confirming compliance with ISO 4427 and
providing details of the type testing undertaken by an
independent third party in accordance with sections 7 and 8 of
ISO 4427 Part 3.
g. The pipe manufacturer shall provide the Engineer with a copy
of the batch release tests i.e. all those tests listed above, with
each batch of pipes or fittings that is delivered to site.
h. Prior to delivery of pipes the pipe manufacturer shall provide
the Engineer with copies of all the test results and certification
required by ISO 4427, this specification and the ITP, but which
are not covered by the above batch testing requirements.
These documents shall comprise the Type Test Report.
i. The Type Test Report shall include a copy of the raw material
manufacturer's "Certificate of Quality Control Testing" covering
each batch of raw material used for manufacturing pipes
produced under this specification.
j. The pipe manufacturer shall ensure that all the applicable
codes and standards are available at their facility for the
Engineers reference during any visit or inspection.
k. The pipe manufacturer shall provide full assistance and co-
operation for any inspection, when required by the Engineer or
by an inspector appointed by the Engineer.
l. The Engineer may reject any item that does not successfully
pass the required tests or fully comply with the requirements of
this specification. When a pipe or fitting is rejected, the items

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manufactured immediately before or after shall be carefully

examined and tested at the direction of the Engineer. If further
defects are found, the entire batch shall be rejected.
m. All pipes and fittings shall be visually inspected by the PE
Welding Inspector before incorporation in the Works.
n. In addition to those tests specifically required, the Engineer
may request additional samples of any material for testing by
the Engineer and all expenses incurred in obtaining samples
for testing shall be borne by the Contractor at no additional
cost to the Contract

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