Final - Draft Specificaion - P.C.C.P1

INDEX
Item notations Description of Items Page No.

1 Introduction 1
2 Applicable IS Codes 1
3 Raw Materials 2
4 Manufacturing of Pipes and Specials 3
5 Sampling criteria for Selection of Pipe for Testing 4
Purpose
6 Pre Delivery Testing of Pipes 4-7
7 Marking on Pipes 8
8 Transportation of Pipes 8-9
9 Stacking of Pipes at Site 9
10 Valves 9-10
11 Post-delivery testing of pipes 10
12 Site Preparation 10-12
13 Excavation for Pipe Trenches 12-13
14 Laying of Pipes 13
15 Jointing of Pipes 13-14
16 Field Testing Of Pipeline System 14-15
17 Backfilling of Pipe Trenches 15-16
18 Permanent markings of Pipe alignment 16
19 Third Party Inspection 17-18
20 Quality Control and Quality assurance 18-19
21 Operation, Maintenance and Handing over of the 19-20
System to WUA
22 Mode Of Measurement and Payment 20-21
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D:\PDN 24042019\PDN 24042019\New folder\(Final) Draft Specificaion_P.C.C. 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.
2.0 Applicable IS Codes

The manufacturing, testing, supplying, laying, jointing and testing at work sites of
PCCP 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 PCCP Pipes form part of these
Specifications.
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&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: 7322 Specifications for Specials for Steel Cylinder Reinforced Concrete pipes
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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
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.
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 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
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4.0 Manufacturing of Pipes and Specials
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.
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5.0 Sampling criteria for Selection of Pipe for Testing Purpose
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.
Table No.1 Scale of Sampling and No. of Acceptable defective tests
(Reproduced from IS 784)
6.0 Pre Delivery Testing of Pipes
Pipe selected as per sampling criteria mentioned in above para 5.0 are subject to
following tests before delivery from factory.
1) Steel Cylinder Test.
2) Dimensions - Length, Internal diameter, Core thickness, straightness and finish.
3) Hydrostatic Factory Test
4) Permeability Test on Coating
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.
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
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Table 2 Nominal Internal Diameter and Minimum Core Thickness of Pipes
(Reproduced from IS 784)
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.
6.2.3 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 following Table No.3
Table No.3 : Minimum wall thickness of joint rings.(reproduced from IS 784)
Nominal Internal Diameter Minimum wall thickness of joint
(mm ) rings. (mm )
200 5.0
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(mm ) rings. (mm )
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
2100 12.00
2200 12.00
2300 14.00
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(mm ) rings. (mm )
2400 14.00
2500 14.00
6.2.5 The deviation from straight line taken between two points one meter
apart, along the pipe barrel shall not exceed 5mm.
6.2.6 The pipe shall be free from local depressions or bulges greater than
5mm extending over a length, in any direction.
6.3 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.
6.4 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
hydrostatic factory test. In case this is done later, then the pipe has to be kept
wet for 48 hrs prior to test.
6.5 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.
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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. Pressure rating.
3. Nominal diameter
4. Lot/batch No. of manufacturer.
5. BIS certification mark.
6. Third Party Certification mark for each lot
7. Name of Department/Project for which pipes are manufactured.
8. Any other important matter that the manufacturer or purchaser deems fit to be
inscribed.
8.0 Transportation of Pipes

Following precaution shall be taken during transportation of pipes
• 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.
• 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.
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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.
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
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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
• 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 forgoing para 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 unuseful 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
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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
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
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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. Unuseful 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.
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.
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
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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 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.
• 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 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.
15.0 Jointing of Pipes
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.
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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
16.0 Field Testing of Pipeline system
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.
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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 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.
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.
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 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.
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(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 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.
18.3 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 the 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.
P. Pipe Revise.docx
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 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.
P. Pipe Revise.docx
(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.
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
P. Pipe Revise.docx
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.
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
P. Pipe Revise.docx
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 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.
22.0 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
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 & hydrostatic testing
of pipeline 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.
P. Pipe Revise.docx
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.
----------***----------
P. Pipe Revise.docx

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INDEX

Item notations Description of Items Page No.

2.0 Applicable IS Codes

IS: 784 Specifications for Prestressed Concrete pipes (Including specials)

3.6 Steel plates for Cylinders, Joint rings and Specials

• Fabrication & hydrostatic testing of steel cylinder as per required size

Cross-section of PCCP Pipe Joint

6.0 Pre Delivery Testing of Pipes

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

6.2.3 Minimum wall thickness of steel cylinders shall be 1.6 mm

6.3 Hydrostatic Factory Test

8.0 Transportation of Pipes

• Pipes manufactured at factory are to be carried to the site of work directly or

9.0 Stacking Of Pipes at Site

10.1 Air Valve :

10.2 Scour Valve :

10.3 Control Valve :

Common types of control valve are as given below.

11.0 Post-delivery testing of pipes

12.0 Site Preparation

12.4 Fixing Permanent Benchmark

1. Total station and its accessories 1 set

13.0 Excavation for Pipe Trenches

14.0 Laying of Pipes

15.0 Jointing of Pipes

16.0 Field Testing of Pipeline system

17.0 Backfilling of Pipe Trenches

18.0 Permanent markings of Pipe alignment

19.2 Testing of materials

20.0 Quality Control and Quality assurance

Sr. No. Personnel with Qualification Nos.

setup by the contractor.

21.0 Operation, Maintenance and Handing over of the System

22.0 Mode of Measurement and Payment

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