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Quality Assessment of High Density Polyethylene Pipe in Department of

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DOI: 10.24321/2393.8307.201803

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 Journal of Advanced Research in Civil and Environmental Engineering
Volume 5, Issue 4 - 2018, Pg. No. 18-33
Peer Reviewed Journal
Research Article

Quality Assessment of High Density

Polyethylene Pipe in Department of Water
Supply and Sewerage
Anjay Kumar Mishra1, Lokendra Prasad Yadav2
1
Visiting Faculty and Management Consultant.
2
Division Chief, Water Supply and Sanitation Division Office, Saptari, Nepal.
DOI: https://doi.org/10.24321/2393.8307.201803

Abstract
Before fiscal year 068/69, quality of procured pipes was not assessed in Department of Water Supply and
Sewerage. Those High Density Polyethylene Pipes might not conform to quality standards and might have
been reducing project life. Overall objective of this research was to analyze the quality of HDPE pipe based
on laboratory test.

All 21 set of test specimen result from different manufacturers have been analyzed’. The collected data
were compared to the standards provided by Nepal Bureau of Standards and Metrology, which is NS 40-
2042. This study was based on both qualitative and quantitative information gathered from visual and
laboratory tests. NS 40 was published in 1983 and modified in 1985. Since then it is the document that
governs Nepalese High Density Polyethylene Pipe industries. HDPE pipes produced from PE 100 are 47.97
percent lighter than PE 63. So, it should be adopted by Nepal Bureau of Standards and Metrology. PE
100 is only 5.27 percent more expensive than PE 63, so department should initiate to reduce the price of
High Density Polyethylene Pipe. 2 and 2.5 kg pressure rated pipe are obsolete in procurement. As per the
laboratory tests, it was found that Nepalese High Density Polyethylene Pipes met the quality standards.
From the test analysis, it was also found that manufacturers intentionally lowered the weight than average
and remained in the lower range to avoid failure in the laboratory test.

Test certificates as per NS 40 should be mandatory in the frequency set by Nepal Bureau of Standards and
Metrology. Office chief and Engineer should be assigned for quality assurance. Length and weight both
should be considered in procurement process. Regional laboratory for High Density Polyethylene Pipe
testing should be established by DWSS. Transportation cost of High Density Polyethylene Pipe should be
based on analysis of transportation from truck up to the nearest road head. High Density Polyethylene
Pipe fittings should be purchased based on the detailed drawing of pipeline network and actual need basis.

Keywords: Dimension, Weight, Hydraulic Characteristics, Reversion Test, Methods for Supply of Pipes
Introduction (HDPE) pipe HDPE pipes. Total budget in FY 2069/70 for
these projects was NRs. 2.40 billion and total expenditure
The Department of Water Supply and Sewerage (DWSS) was 2.30 billion. Since its establishment in 1972 AD, DWSS
is leading organization in water supply sector. It has been has been purchasing large amount of HDPE pipe. In FY
facilitating to implement 1303 number (Devkota, 2013) of 2069/70 the length of pipe purchased by DWSS was about
piped water supply projects in Nepal. In FY 2069/70 about 2805 km. It was quite surprising that DWSS in a history had
100% of DWSS’s projects use High Density Polyethylene hardly conducted any pipe test and had been using HDPE

Corresponding Author: Anjay Kumar Mishra, Visiting Faculty and Management Consultant.
E-mail Id: anjaymishra2000@gmail.com
Orcid Id: https://orcid.org/0000-0003-2803-4918
How to cite this article: Mishra AK, Yadav LP. Quality Assessment of High Density Polyethylene Pipe in Department of Water Supply
and Sewerage. J Adv Res Civil Envi Engr 2018; 5(4): 18-33.

Copyright (c) 2018 Journal of Advanced Research in Civil and Environmental Engineering
(E ISSN: 2393-8307 I P ISSN: 2394-7020)

19
pipes without any conformity to quality by itself. In FY
2068/69, DWSS wished to test pipe quality and thus sent
an official instruction to its district offices to get conformity
before accepting the purchased pipes.
There are around twenty-four HDPE manufactures in
Nepal that has been producing HDPE pipe for water Supply
Projects. The quality conformity on HDPE is governed by NS
40 and there is a provision that it should be monitored by
Gunastar Tatha Naptaoul Bibhag (Nepal Bureau of Standards
& Metrology-NBSM). The DWSS does not have its lab facility
for HDPE pipe testing rather. It intended to use facility of
NBSM, later on DWSS realized that the NBSM’s capacity
was not that much developed to meet the huge need of
DWSS. The DWSS found that NBSM may take one and half
year to test all the sampling of pipes it purchased. Then
DWSS decided to use the manufacturers’ lab facilities itself
under the strict supervision of the representatives of DWSS.
Since long period, supplied HDPE pipe quality was not tested
by purchaser and it was considered to be conformed to
quality. In general, lab reports and other justifications were
not demanded prior to FY 2069/70. Service life of HDPE
pipe is considered to be 50 to 100 years by designers in
Nepalese context. However, the quality of HDPE pipe during
purchase has to consider for maintaining the dynamism of
quality advancement in this sector. Moreover, DWSS, the
largest purchaser in Nepal has no system established for
quality control and routine quality check.
Overall objective of this research was to analyse the
suitability of NS 40 for identifying quality gap of production
of HDPE pipe based on laboratory test.
Literature Review
• General
Manufacturing of HDPE Pipe
Profile wall HDPE pipe is generally produced with one
or more variations of a vacuum forming process or an
extrusion process. Fittings are generally produced utilizing
a blow, vacuum, injection or a rotationally molding process.
Figure 1
Single screw extruders are selected for manufacture of HDPE
pipe because they have adequate mixing capabilities; they
also have the ability to overcome the considerable shear
resistance of the molten resin at lower melt temperatures
(than is the case for twin screw Machines also used for
extrusion of plastics). Running between 75 and 150 rpm,
Mishra AK et al.
J. Adv. Res. Civil Envi. Engr. 2018; 5(4)
outputs are in excess of 1500 lb/hr for the most common
profiles. Single screw extruders used in Profile extrusion
typically range from 1 to 6 inch diameters.
The viscosity, melting point, thermal sensitivity and shear
heating qualities of the molten resin all affect the quality
of the extrudate. On leaving the die, the hot and flexible
extrudate is shaped and cooled. Uniform and gradual
cooling with air and chilled water inhibits unwanted
variations in wall thickness and wrapage of the end product.
After producing the pipe from extruder is is marked with
brand name and other information required.
Various forming techniques are available. Vacuum forming
to an external mold creates the corrugated profile. Sectional
breakaway clamshell molds riding on a closed loop track
provide the means for manufacture of a continuous run
of pipe (Gabriel, 2003).
For assuring project success, Time, Cost and Quality are
highly focused. Labour productivity is under improvement
through Operational inefficiency should be reduced by
overcoming the factors of low productivity for enhancing
the productivity (Maskey and Mishra, 2018). So, it is time
to overcome the serious issue of time overrun among
the government undertaking projects. The severe times
overrun in the projects under study were actually due to
the reason that Ideal time for completion of the project
were awarded during contract agreement (Mishra and
Bhandar, 2018).Similarly, cost overrun issue can be solved
by Trial mix design technique should be promoted so that
the construction activity could become more economical
without compromising the quality(Mishra and Chaudhary,
2018 a). Batching plants should be used in sites for achieving
good control in quality of concrete while mixing relative
ingredients of concrete (Mishra and Chaudhary, 2018 b).So,
many more research are necessary to maintain quality
of construction. Here HDPE as construction material is
focused.
• Pressure Ratings of Polyethylene (PE) Pipes
The most common materials used in the production of
pipes are:
Medium Density Polyethylene with a strength classification,
PE80, which refers to a pipe which has minimum 50 year
strength of 8MPa. This enables operation at pressures up
to 12bar.
High Density Polyethylene with a strength classification,
PE100, which refers to a pipe which has minimum 50 year
strength of 10MPa. This enables operation at pressures up
to 16 bars (Interplast, 2013).
The differences in the naming of the raw material have
come through the raw material suppliers over the past years
as the differentiation between the PE materials developed.
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Mishra AK et al.
J. Adv. Res. Civil Envi. Engr. 2018; 5(4)
Table 1.Naming of PE materials
Old Name New Name
LDPE PE40
MDPE PE80
HDPE PE63, PE80 2nd generation and PE100
3rd generation
• Quality Requirement of HDPE Pipe by DWSS
The DWSS, in its tender specification document, had set
the following pipe quality requirement for HDPE pipe:
Materials and Workmanship
General Requirements
Materials
Term “materials” shall mean all materials and articles of
every kind whether raw, processed or manufactured which
are used in manufacture of the Goods to be supplied under
the Contract.
Composition
The pipes shall be extruded from HOSTALIN GM 5010 T.2
or equivalent approved compound consisting of virgin
polythene in which carbon black and a suitable non-toxic
anti-oxidant are evenly dispersed.
The Client may ask to the suppliers to produce certificate of
evidence of the original raw materials used for producing
pipes and also the evidence of these materials imported
or purchased.
All materials shall be new and of the kinds and qualities
described in the clauses hereof appropriate to the particular
item and shall be at least equal to approved samples except
that alternative materials may be accepted provided the
supplier has at the time of tendering:
• Drawn particular attention to the deviation from the
specification in his tender and provided particulars
of the alternative material offered at the time of
tendering,
• Substantiated to the satisfaction of the Purchaser
that the material offered is equal or superior to the
material specified for the use to which it in to be put
and has obtained from the Purchaser approval in
writing to its use.
Where materials to be used for any component have not
been laid down in the specification, the manufacturer shall
use only those materials in such compositions as have
been proven in actual service to be the most suitable for
the particular purpose. All pipes shall be smooth, clean
and free from all defects.
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20
The supplier must name the manufacturer(s) at the time of
tendering from whom he proposes to obtain any material
under the contract. As a proof, he should also include a
“Letter of Consent” from the manufacturer(s) stating his
acceptance to sell the material to the supplier on award
of the contract. Normally, the material supplied should be
the product from the quoted manufacturer(s). However, in
situation beyond the control of the supplier, the Purchaser
may consent to accept material from other manufacturer;
provided he is satisfied, that the new experienced and
capable to produce the material and that the product
is either equivalent or superior to the product from the
previously agreed manufacture. No orders shall be placed
with the newly named manufacturer without the written
consent of the Purchaser.
Samples of Materials and Tests on Samples
The Supplier shall provide to the purchaser three certified
copies of the results of any routine analyses or tests carried
out by him or his manufacturer on materials used in the
manufacture of the Goods when and if asked by the
purchaser.
Figure 2.Granules of HDPE pipe at Hisi
Factory and Sacs
In addition, when and if required by the purchaser, the
supplier shall provide samples of all or any materials used
in the manufacture of the goods. In addition, shall carry
out any specified test on the said materials as may be
required by the purchaser at the place of manufacture or
at a laboratory approved by the purchaser and shall provide
to the purchaser within seven days of each such test three
certified copies of the results of the analysis or test.
Samples shall be submitted and tests carried out sufficiently
early to enable further samples to be submitted and tested if
required by the Purchaser. The Supplier or his manufacturer
shall prepare the necessary test pieces and supply all labor,
appliances, testing apparatus and everything necessary for
carrying out all specified tests.
The supplier shall give the purchaser 14 days’ notice in
writing of the date on which any of the samples will be
ready for testing or inspection and unless the purchaser
shall attend at the appointed place within the said 14 days,
the test may proceed in his absence.

21
Approval by the purchaser as to the placing of orders for
materials or as to samples or tests shall not prejudice any
of the purchaser’s rights under the contract.
Test Certificates
Test certificates in triplicate shall be provided by the supplier
for each consignment of pipe supplied, giving the process
of manufacture and the results of the specified tests.
Similar certificates in triplicate shall be provided by
the supplier in respect of materials to be used in the
manufacture of the pipes giving the process of manufacture,
chemical analysis (where relevant) and the results of the
specified tests. The material shall be suitably marked to
enable it to be identified from references on the certificates.
Any materials subject to test incorporated in the
manufacture of the pipes before the Purchaser has received
a satisfactory test certificate shall be at the supplier’s risk.
Independent Tests
The purchaser or his designated agent reserves the right
to inspect and carry out any independent tests he may
deem fit on the completed pipes or on any material to be
used in the contract at any stage of manufacturing in the
plant or delivery, in addition to those tests specified to be
made by the manufacturer.
Any samples of materials, which may be required for such
tests, shall be provided by the supplier at no extra cost to
the purchaser.
The cost of making any such independent tests shall
be borne by the purchaser, unless it is shown that the
workmanship or materials under test are not in accordance
with the specification, in which case the cost of the tests
shall be borne by the supplier.
Any materials, workmanship or completed pipes, which are
shown by such independent tests not to be in accordance
with the Specification, shall be rejected, notwithstanding
any previous certificate, which may have been provided.
Rejected Goods
Any goods delivered to the site which have been rejected
by the purchaser, shall immediately be removed from the
site, at the expense of, the supplier. Replacement or rejected
goods shall be made as soon as possible but in no case
exceeding forty- five (45) days from the time of rejection.
Any pipes, which have been rejected, shall be marked in a
distinctive manner, which shall preclude any possibility of
their use for the purpose for which they were supplied. Such
pipes may be submitted for retest following the correction
of any defects, where such correction is permitted by the
purchaser.
Mishra AK et al.
J. Adv. Res. Civil Envi. Engr. 2018; 5(4)
Standards
All materials, workmanship and components shall, where
applicable and unless otherwise stated in the contract,
comply with either:
• A relevant Nepal, Indian, British or American Standard
current on the date fixed for receipt of tenders,
• Any other internationally accepted equivalent
standards that, in the opinion of the purchaser, are
equal to or better than the specified standards.
Nepal Standard NS: 40-2042 published by Nepal Bureau
of Standards and Metrology.
Indian Standards IS : 4984 - 1995 published by Bureau of
Indian Standards, Manak Bhawan, New Delhi, India.
British Standards BS 3284: 1976 published by British
Standards Institution (BS), British Standards House, London
WI, England.
The acceptance of a tender based upon a standard or
code of practice proposed by the supplier shall only
signify the purchaser’s general approval to the use of
such standard or code of practice. In addition, shall not
signify acceptance by the purchaser of any materials or
workmanship subsequently found to be inferior to that
specified in the corresponding standard or code of practice.
Supply and Marking of Pipes
The pipes shall be supplied as coils with a minimum inner
diameter of 25 times the OD of the pipes (except 2,2.5,
and 4 kg/Sq.cm. pressure ratings) for OD sizes of 16mm to
50mm as given below and for higher OD sizes in lengths of
five/six meters. The pipes may also be supplied in other
lengths where so agreed between the supplier and the
Purchaser. The ends shall be cut at right angles to the pipe
axis and shall be plugged or covered.
A continuous line between 2mm to 5mm wide must
be indelibly and clearly marked along the pipe surface
according to the following code:
Figure 3.Marking Machine at Hisi
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Mishra AK et al.
J. Adv. Res. Civil Envi. Engr. 2018; 5(4)
• 2.5 kg/cm2 working pressure - Red line
• 4.0 kg/cm2 working pressure - Blue line
• 6.0 kg/cm2 working pressure - Green line
• 10.0 kg/cm2 working pressure - Yellow line
Each pipe shall also have the following information marked
on it: On every meter length.
Item number; pipe size - outer diameter; Series in Kgf/cm2;
Weight; Length; NS, IS, BS, etc., or relevant authoritative
standards mark.
The method of marking shall be such as to ensure that all
of the information will remain legible after shipping, local
haulage and storage in the open.
Testing of Pipes before Delivery
Tests
At the place of manufacture; hydraulic tests, reversion tests
and internal pressure creep tests shall be carried out on
ten random samples from each pipe series and diameter
spaced throughout the manufacturing period.
The requirement may be reduced where a small length
of a particular pipe diameter and series is to be supplied.
The working pressures for the various pipe series shall be:
• Series I 2.0 kgf/cm2
• Series II 2.5 kgf/cm2
• Series III 4.0 kgf/cm2
• Series IV 6.0 kgf/cm2
• Series V 10.0 kgf/cm2
Tests shall be witnessed by an independent inspection agent
or purchaser’s agent, to be appointed by the purchaser,
who shall approve the tests on behalf of the purchaser.
Site Inspection and Testing
All goods will be inspected after delivery to site and the
purchaser will reject any item that is damaged or not
complying with the specifications (DWSS, 2013).
Nepal Standard (NS 40-2042)
Nepal standard has quoted in its permeable that NS wants
to make coordination with Indian standard and other
international standards (Nepal Standard, 2042 BS). This
standard was published in 2040 and modified in 2042 BS.
• Requirements for Raw Material
• General Requirements of pipe
• Dimension of Pipe
• Weight of Pipe
• Hydraulic Characteristics
• Reversion Test
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22
• Methods for Supply of Pipes (Nepal Standard, 2042 BS)
From above parameters of three different countries, they
are nearly similar to each other. In British standard there
are two parameters which is more relevant which are
short-term pressure test and requirement of material as
anti-oxidant.
NS 40 has following test schedules
Type test
It is the test performed when
• New composition in raw material
• Technology alteration
• New production of size and series
Acceptance test
It is the test performed when
• For single consignment
• Same technology
• Same situation
Parameters Selected by DWSS
DWSS is government department which established its
own testing schedule for fast test and delivery of HDPE
pipe under the Nepal Standard. DWSS has formulated
specification which is available in DWSS. Due to the
inefficiency of the institutional capacity of DWSS, NBSM
and manufacturers’ lab the DWSS has selected only the
following parameters for pipe testing. For this DWSS has
adopted parameters which wants to conform quality under
Nepal Standard.
Outer Diameter
Outer diameter is measurement of outer diameter of
manufactured pipe. This is measured from pie tape
available to measure diameter from circumference of the
manufactured pipe.
Figure 4.Diameter measurement in Hisi factory Lab
This type of tape gives the direct diameter measurement
calibrated by its circumference. Hence it is helpful to
measure pipe diameter even if the pipe is distorted
elliptically or oval.

23
Ovality
Ovality is the measurement of distortion of pipe diameter
in two different perpendicular direction. If the pipe having
diameter more than other side it can be said to have more
ovality. According to NS, ovality expressed in percentage
and it must be within three percent. Difference between
diameters of pipe in perpendicular direction is compared
to minimum thickness of HDPE pipe.
In telecommunications and fiber optics, ovality or
noncircularity is the degree of deviation from perfect
circularity of the cross section of the core or cladding of
the fiber. In measurements, ovality is the amount of out-of-
roundness of a hole or cylindrical part in the typical form
of an oval (Hehre & Ohlinger, 2008). When HDPE pipe is
not strong enough to withstand elliptical shape is formed
which can be measured at the end of any side.
Pipe Thickness
Thickness shows the quantity of material used for the
production. Pipe thickness is the wall thickness measured
from micrometer. It must be smooth and almost single size
with no variations.
Figure 5.Pipe Thickness Measurement by
Micrometer in Hisi Lab
If the variation is high it must take account of least thickness.
In production process thickness can be changed when
production is interrupted.
Weight per Meter
Weight per meter test is the measurement of weight. It has
upper limit and lower limit. It must conform to lower limit.
For coiled pipes it can be measured by measuring whole
bundles’ weight and divided by its length to get unit weight.
Hydraulic test
Hydraulic Pressure test is the test for the specified pressure
rating of the pipe. Specified pressure is applied to the test
specimen for uninterrupted 48 hours in water bath of 80
degree temperature. For this test, air tight test specimen
is prepared by connecting Controllable internal Hydraulic
pressure. In this apparatus sealing plug is so prepared
the internal pressure can elongate pipe in axial direction
without obstructing.
The length of test specimen will be 10 times of the Outer
Mishra AK et al.
J. Adv. Res. Civil Envi. Engr. 2018; 5(4)
Diameter of particular pipe, the length of test specimen
should be not less than 250 mm and not greater than
750 mm.
Reversion test
Reversion test is the measurement of length variation
by temperature. If we are using our pipe in adverse
temperature which may be either high temperature
zone like Terai region or low temperature zone like upper
Himalaya region. There pipe varies in pipe length. So the
pipe must conform to variation. If pipe gains its original
length to limit by standard it can be called to certify.
Figure 6.Reversion Test Length Measurement
at Hisi Lab
For this pipe of certain measurement is taken and marked.
After that test piece is placed in oven to the temperature of
110 degree centigrade for half an hour, after that it is taken
out and placed to cool down. After that marked distance
is measured and variation is calculated.
Weldability test
The weldability, also known as joinability, of a material
refers to its ability to be welded at the temperature of
200 degree centigrade. For test of weldability NS 40 says
that it must be visually tested which is nondestructive
test. In visual test it must be jointed smoothly at specified
temperature with forming a band on its joint circle.
Many metals and thermoplastics can be welded, but some
are easier to weld than others. Weldability is a measure of
how easy it is to make a weld in a particular parent material,
without cracks, with adequate mechanical properties for
service, and resistance to service degradation. (Twi-Global,
2014).
Figure 7.Weldability Test Specimen
Parameter Summary of NS 40 for Quality Production
The entire test specified by NS 40-2042 is nondestructive
test. Scrap work of damaged pipe can be made granules by
melting and added to the new granules up to 10 percent.
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Mishra AK et al.
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It electricity is continuous the scrap pipe production is 7 40 mm 6 Coils 100

negligible according to informal talk with technician involved
in the intrusion process of the pipe in both of the factories. 8 40 mm 10 Coils 100
Ovality which is the inspection of circularity of produced 9 50 mm 4 Length 5
pipe can be visually differentiated. After differentiation it 10 50 mm 6 Coils 100
can be measured. Color of HDPE pipe must be black for 11 50 mm 10 Coils 50
water supply.
12 63 mm 2.5 Length 5
Table 2.Supply Requirements
13 63 mm 4 Length 5
S.No. Parameter Requirements 14 63 mm 6 Coils 50
1 Requirements • Density not less than 15 63 mm 10 Coils 50
for Raw Ma- 0.955 gm. per cubic cm 16 Great- mm All Length 5
terial • No harmful Chemical er than
Carbon Black 2 to 3 63
percent
• Melt Flow Index 0.6 gm. Method of supply refers to the process of putting pipes for
per 10 minute loading and sending by appropriate means of transportation.
• Moisture 0.1 percent Small sized pipes can be coiled for reduction of linear space
• Scrap less than 10 per- for the extent they don’t distorted its original shape. So
cent up to 32 mm all the pipes can be coiled. After 32 mm pipe
2 General Re- • Must welded at 200 higher PN valued pipe can be coiled and PN 4 cannot be
quirements of degree centigrade coiled. So these pipes must be cut in length for supply.
pipe • Black Color
• No Cracks No twists No
mark along Length
3 Dimension of • Outer Diameter and
Pipe Thickness as per Annex C
• Ovality less than mini-
mum thickness of Pipe
4 Weight of Pipe As per Annex C
Figure 8.Coiling of HDPE Pipe in Factory
5 Hydraulic No cracks Coiled pipes are easy to handle in remote part of the country
Characteristics No deviation
so sometimes estimators tries to justify transportation cost
No Segregation during Inter-
and estimates higher PN rated pipe than required.
nal creep Rupture Test
Table 4.Pipe Procured By DWSS in FY 2069/070
6 Reversion Test Less than 3 percent
7 Methods for As per Table 2.3 S.No.  Development Target Progress
Supply of Region (Km.) (Km.)
Pipes 1 Eastern 615.00 612.81
2 Central 532.90 659.30
Method of Supply of Pipe
3 Western 657.79 679.84
Table 3Parameters’ Summary by NS-40, 2042
4 Mid-Western 530.32 528.95
SN Size Unit Pres- Meth- Length(m) 5 Far Western 324.66 324.40
sure od of
in Kg Supply DWSS Total 2660.67 2805.30
Per Source: (Devkota, 2013)
Sq.
cm Pipe Purchased By DWSS in FY 2069/070
1 16 mm 10 Coils 300
In progress review meeting for the Fiscal year 2069/70 it was
2 20 mm 10 Coils 300 stated that all the pipes were procured from competition
3 25 mm 10 Coils 200 from respective districts. And another major highlight for
4 32 mm 6 Coils 200 the HDPE pipe was DWSS completed lab test for the first
5 32 mm 10 Coils 100 time in the history of DWSS.
6 40 mm 4 Length 5 From the above table it is seen that far western region

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 Mishra AK et al.
25 J. Adv. Res. Civil Envi. Engr. 2018; 5(4)

had purchased the lowest amount of HDPE pipe. No
manufacturers are present in far western they have to
depend upon the factory from other region. Similarly
western region procured the largest length of HDPE pipe
From the above table it is also clear that pipe procured is
greater than the target set by deportment. This might be
due to emergency procurement during flood season for
the maintenance purpose.
Methodology
Research Design
this study was based on laboratory results carried by
researcher himself and data available at Department
of Water Supply and Sewerage. The collected data are
compared to standards provided by Nepal Bureau of
Standards and Metrology, which was NS 40-2042. This
research was applied to explain properly the different
findings, which came from test. This study was based on
both qualitative and quantitative information basically
gathered from visual and laboratory test. The present
study was quantitative in nature that attempted to study
of quality conformance of HDPE pipes in Nepal.
factories, DWSS got test report from three manufacturers
in F/Y 069/70, which all were incomplete. They sent only
hydraulic test report so all samples from western part are
omitted for further analysis. From eight samples researcher
collected data from two factories which were Hisi Polythene
and Plastic Industries Pvt. Ltd, Balaju Industrial District,
Balaju and Yeti Plastic Industries Pvt. Ltd, Bhaisepati,
Janagal, Kabhreplanchok. Remaining six samples from
other part of country were provided by DWSS. From
the selected eight factory test result, Chitwan Polypipe
Industries, Ramghat, Chitwan have lowest set of data i.e.
twenty-one. So, researcher chose twenty-one set of data
from each for analysis. Nepal Standard, 2040-42 is adopted.
Data Analysis
First data from laboratory obtained by researcher was
tabulated. The data from DWSS was collected and
tabulated for further analysis. From the available data set
the parameters were as per acceptance test as stated in
literature.
Results and Discussions
Suitability of NS 40-2042

Study Area Location of HDPE Pipe Industries

Study area was all manufacturers of HDPE pipe in Nepal From the Table 4.1, it was found that 62.5% industries
which was Nepal Standard (NS) quality awarded by NBSM. are located in central region, 20.8% are located and Mid-
Among them eight factory (33%) was taken as sample. It Western, Eastern and Mid-Western have 8.3% and Far-
was selected from Western Region, Central Region and Western region has no industries till 2013.
Eastern Region of Nepal.
It was seen that most of the industries were in middle of
Study Population and Sample Selection country because it is convenient to supply most part of
country easily than any other part of Nepal.
In this study, samples were taken from stratified random
sampling method. The sample manufactures was selected In far western it still has to depend on other part of country
from diverse region of Nepal. Far-Western region of Nepal for the supply of HDPE pipe. It is very difficult to establish
do not have any HDPE pipe manufacturer till yet. Therefore pipe manufacturing industries in hill area and also to
no sample was available from Far-Western region of Nepal. transport of pipe in hill part is also more expensive either
In western region, there are five factories. Among five from truck or manually comparatively.
Table 5.Sample Selection
Region Population Test Result Available Sample Test By Re-
No. % Complete Partial No. % searcher
Central 15 62.50 7 1 6 40.0 2
Eastern 2 8.33 1 - 1 50.0 -
Mid- 2 8.33 1 - 1 50.0 -
Western
Western 5 20.83 - 3 - - -
Far-Western - - - - - - -
Total 24 100.00 9 4 8 33.3 2

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NS 40 published in 1983 and since then it is the document

Table 6.Locations of Industries
that governs Nepalese HDPE industries.
SN Region Num- Percentage Remarks
ber Granule Composition
1 Eastern 2 8.3 Table 8.Raw Material Specifications

2 Central 15 62.5 S.No. Standard or Material Description

3 Western 5 20.8 Document
4 Mid-West- 2 8.3 1 Department HOSTALIN GM 5010 T.2 or
ern of Water virgin polythene in which
Supply and carbon black and a suitable
5 Far-Western - - No factory Sewerage non-toxic anti-oxidant are
Total 24 100 evenly dispersed.
Table 7.Comparisons of Nepalese 2 Hisi Polythene HOSTALIN GM 5010 T.2
Standard with Indian Standards and Plastics
3 Nepal Virgin polythene in which
S.No Partic- NS 40- IS 4984:1995 Remarks Standard (NS carbon black is 2-3%, MFI-
ulars 2042 (Reaffirmed 40-2042) maximum 0.6g/10 minute,
2007) Moisture-maximum 0.1%,
1 Wall Single Three dif- NS 40 thick- Rework - maximum 10% and
thick- thick- ferent types ness matches a suitable non-toxic anti-
ness ness of thickness (r=0.999) oxidant are evenly dispersed.
according with IS 4984 , 4 Indian Pipe shall be classified
to grade of PE 63 Standard (IS according to grade of
material 4984-1995) material i.e. PE63, PE80
2 Pres- 2, 2.5, 2.5, 4, 6, 8, IS 4984 with- and PE10. Virgin polythene
sure 4, 6 10, 12.5 and drawn PN 2 in which carbon black is
rating and 10 16 and added 2-3%, MFI-Maximum 0.41-
12.5 and 16 1.10 g/10minute, Rework -
in 2006 maximum 10% and a suitable
3 Nom- 16 mm 16 mm to IS 4984 add- non-toxic anti-oxidant are
inal to 500 1000 mm ed 800mm, evenly dispersed.
Diam- mm 900mm,
Materials used for manufacture of HDPE pipes have got
eter 1000mm in
advancement according to Indian Standard than past. In
2006
Indian Standard, there is three category of raw material but
4 Grade No Three dif- IS 4984 in Nepal there is no difference of material can be seen either
of grading ferent types updated in Nepal Standard or in departments bidding document or
Raw is avail- of material according to in manufactures document. However, HOSTALIN GM 5010
Mate- able PE63, PE80, ISO Standard
T.2 word is taken in DWSS bidding document that matches
rial PE100
with only a manufacturer’s document. Hostaline is the
5 Oval- Less Fixed accord- IS 4984 has brand name so it should be avoided for fair competition
ity than ing to table lower value in bidding process. Hostalin was not any raw material’s
mini- given by IS of Ovality name but brand name.
mum 4984 than NS
wall Quality Gap Analysis
thick-
ness Visual Test

Comparisons of NS 40-2042 and IS 4984:1995
(Reaffirmed 2007)
IS 4984 was first published in 1968 and revised in 1972,
1977, 1987 and 1995 and after that it got four amendments
till 2006. Indian Standard has changed according to material
available in market that helped to reduce thickness of pipe
wall and also helped to enlarge nominal diameter of pipe.
Visual Test for all pipes found to be as per requirement.
No factory has sent the data as visually defective and no
any observation made during test result of Hisi and Yeti.
As per manufacturers’ statement if power breakdown
takes place then defective pipes may be manufactured
and immediately they remove the defective work. As

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27 J. Adv. Res. Civil Envi. Engr. 2018; 5(4)

manufacturers are allowed to reuse waste up to 10%, they use the defective piece as rework.

No defective pipes can be accepted as per bid document so it is mandatory to remove all defective pipes before lab
test and transportation to purchaser.
Table 9.Visual Test
S.No. Manufacturer Black Color No Cracks No Twist Visual Test Passed
1 Chitwan 21 21 21 21
2 Crystal 21 21 21 21
3 Godawari 21 21 21 21
4 Hisi 21 21 21 21
5 Kamala 21 21 21 21
6 Nepal 21 21 21 21
7 Tondon 21 21 21 21
8 Yeti 21 21 21 21
Total 168 168 168 168
Welding Test
Table 10.Welding Test
S.N0. Manufacturer Temperature (0C) Smooth Jointing Breaking on drop Fail Pass
1 Chitwan 200 21 21 - 21
2 Crystal 200 21 21 - 21
3 Godawari 200 21 21 - 21
4 Hisi 200 21 21 - 21
5 Kamala 200 21 21 - 21
6 Nepal 200 21 21 - 21
7 Tondon 200 21 21 - 21
8 Yeti 200 21 21 - 21
Total 168 168 - 168

Welding Test at 2000c for all pipes found to be satisfactory. No factory has sent the data as defective and no any defective
observation made during test result of Hisi and Yeti.Welded specimen was manually struck with the floor as strong as
possible but no break could be seen in the lab during lab test in both Hisi and Yeti laboratory.

Reversion Test
Table 11.Reversion Test
S.No. Manufacturer Length Temperature Duration in Air Average Percentage >3% < 3%
(mm) (0C) Oven (minute) difference
1 Chitwan 200 110 30 1.12 - 21
2 Crystal 200 110 30 0.44 - 21
3 Godawari 200 110 30 0.93 - 21
4 Hisi 200 110 30 1.05 - 21
5 Kamala 200 110 30 0.86 - 21
6 Nepal 200 110 30 0.44 - 21
7 Tondon 200 110 30 0.97 - 21
8 Yeti 200 110 30 0.74 - 21
Total 0.82 168

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Reversion Test at 1100c for all pipes found to be satisfactory. No pipes was varying more than 3% length measured to
200 mm of test piece and no any defective observation made during test result of Hisi and Yeti.

Ovality Test
S.No. Manufacturer
1 Chitwan
2 Crystal
3 Godawari
4 Hisi
5 Kamala
6 Nepal
7 Tondon
8 Yeti
Total
Table 12.Ovality Test
> than Min. Wall thickness < than Min. Wall thickness Remarks
- 21
- 21
- 21
- 21 Primary Data
- 21
- 21
- 21
- 21 Primary Data
- 168

Ovality measurement at room temperature for all pipes found to be satisfactory. No pipes were beyond NS limit and
no any defective observation made during test result of Hisi and Yeti.

Hydraulic Test
Table 13.Hydraulic Test
S.No. Manufacturer Temperature (0C) Duration (Hr.) Cracks Deformation Leakage Pass
1 Chitwan 80 48 - - - 21
2 Crystal 80 48 - - - 21
3 Godawari 80 48 - - - 21
4 Hisi 80 48 - - - 21
5 Kamala 80 48 - - - 21
6 Nepal 80 48 - - - 21
7 Tondon 80 48 - - - 21
8 Yeti 80 48 - - - 21
Total - - - - - 168

Hydraulic Test at 800c and duration 48 hours for all pipes found to be satisfactory. No pipes were broken during specified
pressure and no any defective observation made during test result of Hisi and Yeti. From the data provided by DWSS,
it was found that four manufacturers has sent only hydraulic test report and all other test have been ignored. During
hydraulic test no cracks were found. Even though a piece was tested by researcher’s own interest for the test specimen
which was series III allowed to 4 kg pressure per squire cm but 10 kg pressure was developed for 30 minutes and it
was not cracked.

Test of Outer Diameter

Table 14.OD Measurement
S.No. Manufacturer Out of Limit Within limit Percent Greater
1 Chitwan - 21 0.30
2 Crystal - 21 0.16
3 Godawari - 21 0.57
4 Hisi - 21 0.41
5 Kamala - 21 0.14
6 Nepal - 21 0.44

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29 J. Adv. Res. Civil Envi. Engr. 2018; 5(4)

7 Tondon - 21 0.61
8 Yeti - 21 0.07
Total - 168 0.34

Outer Diameter (OD) measurements of all specimens are
very satisfactory. All 168 samples have as per NS-40 positive
tolerance. For outer diameter negative tolerance is not
allowed and all the samples from eight manufacturers had
positive tolerances within limit.
Average percentages of greater values are listed in the
table. From the table Tondon Plastics Industries Pvt. Ltd.,
Nepalgunj Industrial Zone has highest average of greater
percentage i.e. 0.61% and likewise Yeti Pipe Industries Pvt.
Ltd., Nasikasthan, Kabhreplanchok has lowest variation from
nominal Diameter (DN) i.e. 0.07%. Hence Yeti’s production
was very consistent to dimension. If the diameter of pipe
was not consistent it creates problem at the time of jointing.
So from the analysis we can say that Yeti’s production
process was very confined.
Weight per Meter Measurement
From the Figure 4.1 Weight Comparision it was seen that
six manufacturers have average variations in negative
direction meaning that they all have weight below average
but fulfilling the requirement of NS 40-2042. Only Godawari
Plastocraft Industries Pvt. Ltd., Hetauda Industrial District
has positive variation from average required by NS 40-
2042 whereas Kamala Polythene and Plastics Ind. Pvt. Ltd.
Mujelia, Janakpur has largest absolute variation of 5.33%
and same value for average variation meaning that all its
product are below average and more than lower limit of
NS 40-2042. On an average absolute variation was 2.75%
contributing average 1.36% less weight.
Average variation in negative direction shows the result that
there is intentional deviation from the standard. NS 40 has
range for weight and thickness. Manufacturer’s products
are in between the range. Test result being in between
range shows positive result in laboratory test. For payment
agreement is done in length basis. The payment for average
weight is done. Unknowingly purchaser paid more than
required in terms of weight. So it will be convincing to
make payment on the actual basis of weight procured.

Figure 9.Weight Comparision

Table 15.Minimum and Maximum Thickness

Manufacturer Minimum Thickness Maximum Thickness
Defective OK Defective OK
Chitwan 1 20 21
Crystal 1 20 21
Godawari 21 1 20
Hisi 21 21
Kamala 21 21
Nepal 21 1 20
Tondon 21 21
Yeti 21 21
Total 2 166 2 166

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Test of Minimum and Maximum Thickness of Pipe Wall

Minimum and maximum thickness of 168 samples showed that 4 samples were defective and out of range. These
defective pipes were not checked before delivery. Although the highest variation was 10% and the same sample meets
all other criteria. Although 4 samples were defective it completed the other tests. Purchaser might have requested for
change the product.

Management survey within DWSS officials

This survey was conducted within DWSS senior Engineers and a sample was taken from another department. This was
all concerned about management related problems of HDPE pipe quality assurance and quality management.

Per Meter Weight Comparisons According to Grade of Material

Table 16.Wall Area Calculation For PN 6
OD Wall Area in mm2 100 Vs. 63 100 Vs. 80
PE63 PE80 PE100
50 551.54 456.76 380.12 45.09 20.16
63 869.24 724.11 592.28 46.76 22.26
75 1240.96 1027.70 849.99 46.00 20.91
90 1765.38 1460.06 1196.00 47.61 22.08
110 2622.48 2189.49 1758.91 49.10 24.48
125 3397.09 2803.05 2278.57 49.09 23.02
140 4234.36 3511.52 2865.38 47.78 22.55
160 5536.71 4580.16 3729.57 48.45 22.81
180 6989.34 5765.69 4707.48 48.47 22.48
200 8610.98 7142.69 5799.10 48.49 23.17
225 10868.15 9001.13 7363.41 47.60 22.24
250 13454.66 11108.66 9043.36 48.78 22.84
280 16862.53 13891.37 11342.40 48.67 22.47
315 21267.83 17581.26 14360.81 48.10 22.43
355 27015.90 22280.76 18202.79 48.42 22.40
400 35085.18 28956.99 23536.53 49.07 23.03
Average 47.97 22.46

The Table 4.4 shows that PE 63 and PE 80 grade raw materials product is heavier than PE 100. For pressure rating 6 Kg
per cm square it is 47.97% heavier and PE 80 is 22.46% heavier. It showed that we can save cost by shifting the granules
from PE 63 to PE 100. For the same rating pipe purchaser paying more than required for weight. Actually purchaser
is said that material is costlier that before and the district rates are available in kg and unknowingly more cost is paid.
Table 17.Wall Area Calculation For PN 10
OD Wall Area in mm2 100 Vs. 63 100 Vs. 80
PE63 PE80 PE100
50 829.38 700.57 578.05 43.48 21.19
63 1300.14 1106.34 919.38 41.42 20.34
75 1857.14 1562.09 1300.62 42.79 20.10
90 2644.09 2233.48 1861.01 42.08 20.01
110 3974.74 3310.11 2754.16 44.32 20.19
125 5093.81 4291.70 3546.73 43.62 21.00
140 6401.78 5382.80 4439.38 44.20 21.25

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160 8339.55 7016.11 5792.31 43.98 21.13

180 10533.10 8865.50 7348.78 43.33 20.64
200 13054.57 10930.98 9063.74 44.03 20.60
225 16444.44 13830.95 11437.75 43.77 20.92
250 20315.14 17071.72 14087.52 44.21 21.18
280 25539.86 21389.19 17646.13 44.73 21.21
315 32200.78 27060.70 22359.50 44.01 21.03
355 40958.33 34332.42 28435.27 44.04 20.74
400 53032.59 44483.18 36836.99 43.97 20.76
      Average 43.62 20.77

Likewise pressure rating 10 kg per cm square PE 63 is 43.62% heavier while PE 80 is 20.77% heavier. These all weight
is taken from Indian Standard.

Price Comparisons According to Grade of Material

Table 18.Price Comparisons with Grade of Material

Material Seller Date Unit Currency Price Percentage

PE 100 ECEBD(Euro) 2013-9-12 MT NRs. 189284.55 4.43
PE 80 ECEBD(Euro) 2013-9-12 MT NRs. 181258.35 Base
PE 63 ECEBD(Euro) 2013-9-12 MT NRs. NA  
 
PE 100 GAIL (INDIA) 2013-9-01 MT NRs. 179216.00 1.82
PE 80 GAIL (INDIA) 2013-9-01 MT NRs. 176016.00 Base
PE 63 GAIL (INDIA) 2013-9-01 MT NRs. NA  
 
PE 100 IOC (INDIA) 2013-9-05 MT NRs. 175640.00 5.27
PE 80 IOC (INDIA) 2013-9-05 MT NRs. 173184.00 3.80
PE 63 IOC (INDIA) 2013-9-05 MT NRs. 166846.40 Base
Exchange Rate on 2013-9-12
1 Euro 133.77
1 INR 1.6

From Table 4.6 it was found that PE 63 is not easily available in market. In European market PE100 was 4.43% expensive
than PE 80, where in Indian market it was less than 2% expensive and all the raw materials are within 5.27 percent
price difference.

Calculation of Saving by Changing HDPE Granules

Table 19Saving Calculation by Granules Shift
S.No. Comparison PE PN Wt. Saving (Percent) Cost above (Percent) Net Profit Average Saving
(Percent)
1 100 Vs. 63 6 47.97 5.27 42.7 40.53
3 100 Vs. 63 10 43.62 5.27 38.35
2 100 Vs. 80 6 22.46 1.47 20.99 20.15
4 100 Vs. 80 10 20.77 1.47 19.3

By shifting from PE 63 to PE80 and PE100 purchaser can save 20.15 percent and 40.53 percent respectively. These prices
are calculated on basis of IOC price analysis. This is the great amount purchaser wasting money for the same rating of
pipe. Although purchaser get over strong pipe more than required.

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Demand of Pipe Series Quality Gap Management

Pipe demand from different district located office has All the procurement process should be performed from
39.88% demands for 6 kg per centimeter square, 10 kg per District offices
centimeter square has 32.14%, 4 kg per centimeter square
has 27.98% and 2.5 and 2.0 kg per centimeter square has Lab test report should be mandatory in the frequency set
no demand. Although low headwater requires low pressure by NBSM.
rated pipe that was ignored and demand has been made
almost zero. Due to poor performance of low pressure References
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Table 20.Pipe Series Demand
S.N. Series PN Number of Samples Percentage Remarks
1 I 2 - -
2 II 2.5 - -
3 III 4 47 27.98
4 IV 6 67 39.88
5 V 10 54 32.14
Total 168 100.00

Conclusions
The specific Conclusion based on objectives of this study
are:
NS 40
• NS 40-2042 needs Amendments According to raw
material advancement and DWSS’ Specification
requires modifications
• HDPE pipes produced from PE100 are lighter 20.77 to
47.97 percent than produced from PE63. So,PE 100 is
expensive only 5.27 percent than PE63.
• By shifting from PE 63 to PE80 and PE100, purchaser
can save 20.15 percent and 40.53 percent respectively
Quality Gap
Acceptance test is compulsory for every purchase according
to NS 40.Purchased HDPE pipe complied to the specification
as per test result but intestinal deviation were found. It
shows that most of the industries are located in the middle
of country. Purchaser of HDPE pipe for 2.5 kg pressure and
2 kg pressure is zero.
Recommendations
NS 40
Amendments should be done NS 40 for following parts:
• Quality of raw material and its standard naming
• Thickness according to raw material
• Omission and addition to pressure rating
• Different Specification according to granule
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