Specification For Construction, Testing & Commissioning of High Density Polyethylene (Hdpe) Pipe System

SPECIFICATION FOR CONSTRUCTION,
TESTING & COMMISSIONING OF HIGH
DENSITY POLYETHYLENE (HDPE) PIPE
SYSTEM
1 27-04-2008 QA/QC
0 02-02-2002 Approved Issue
rev. date Description/issued for prepared authorised
client: ADWEA
project: STANDARD SPECIFICATIONS FOR WATER WORKS
title: SPECIFICATION FOR CONSTRUCTION, TESTING & COMMISSIONING OF HIGH
DENSITY POLYETHYLENE (HDPE) PIPE SYSTEM
project phase: project: document: W-P-SS-017 rev: 0 sheet: 1 of: 35

Table of Contents page
1. SCOPE OF SPECIFICATIONS ............................................................. 3
2. APPLICABLE STANDARDS AND CODES .......................................... 3
3. TECHNICAL REQUIREMENTS ............................................................ 3

3.1 General ....................................................................................... 3
3.2 Pre-Construction Survey ............................................................. 4
3.3 Right-of-Way (ROW) ................................................................... 4
3.4 Crossings .................................................................................... 5
3.5 Clearing, Grading and Backfilling of ROW .................................. 5
3.6 Handling, Hauling, Stringing and Storage ................................... 9
3.7 Trenching .................................................................................. 12
3.8 Pipe Laying and Jointing ........................................................... 16
3.9 Backfilling .................................................................................. 20
3.10 Tying-In ..................................................................................... 22
3.11 Special Crossings/Road Crossings ........................................... 23
3.12 Final Clean-Up of the Construction Right-of-Way ..................... 25
3.13 Encroachments and Working Near Other Utilities ..................... 26
3.14 Detectable Warning Tapes ........................................................ 26
4. TESTING AND (PRE)COMMISSIONING ............................................ 27

4.1 Test Procedure.......................................................................... 27
4.2 Disinfection and Flushing of Water Pipeline .............................. 27
4.3 Pipeline Commissioning ............................................................ 30
5. QUALITY ASSURANCE/Q UALITY CONTROL .................................. 30
6. DOCUMENTATION ............................................................................. 30
6.1 Records..................................................................................... 30
6.2 As-Built Drawings and Pipe Book.............................................. 33
Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR CONSTRUCTION, TESTING & COMMISSIONING OF HIGH
Project phase: project: document: W-P-SS-017 rev: 0 sheet: 2 of: 35

1. SCOPE OF SPECIFICATIONS
This specification covers minimum requirements for the construction, installation and testing
of High Density Polyethylene (HDPE) pipes and fittings including route survey, row,
excavation, stringing, joint fusion, laying, backfilling, etc.
2. APPLICABLE STANDARDS AND CODES
Unless otherwise specified the works shall conform to the following standards and other
standards noted elsewhere in this specification.
Polyethylene (PE) Pipes for Water Supply – Specifications ISO 4427
Plastic Piping Systems for Water Supply Polyethylene (PE) BS EN 12201
Pipelines on land. BS 8010 : Part 1
Pipelines on land design, construction and installation. BS 8010 : Part 2
Disinfecting water mains. AWWA C651
3. TECHNICAL REQUIREMENTS
3.1 General
CONTRACTOR shall prepare detailed Method Statements (MS), i.e. Construction

Procedures, for all described activities, and submit to ADWEA/End users/ENGINEER for
approval. These MS's shall describe in detail how the CONTRACTOR proposes to perform
the various activities to ensure compliance with the requirements as set forward in this
Specification.
CONTRACTOR shall take full responsibility for the stability and safety of all operations carried
out and all methods of work adopted. The CONTRACTOR shall also take full responsibility for
stability and safety of all existing facilities/utilities/roads/etc. affected by any operation, design
and method adopt ed by CONTRACTOR in executing the work.
CONTRACTOR shall be deemed to have inspected the work area(s) and their surroundings
and to have satisfied himself as to the form and nature thereof, including sub-surface
conditions, hydrological and climatic conditions, the extent and nature of the work, the
materials necessary for the completion of the work and the means of access to all the work
area(s).
CONTRACTOR shall be deemed to have obtained all necessary information as above

mentioned as to risks, contingencies and all other circumstances, which may influence the
work.
CONTRACTOR shall, in connection with the work, provide and maintain all lights, safety
barriers, fencing, watchmen (and associate facilities) etc., when and where necessary as
required by ADWEA/End users/ENGINEER or by any duly constituted Authority and/or by the
Client ADWEA

Authorities having jurisdiction thereof for the protection of the work and properties or for the
safety and the convenience of public and/or others. Not withstanding the soil type or method
of construction indicated in the alignment sheets, CONTRACTOR shall use the type of
construction required by the actual soil conditions at site subject ADWEA/End
users/ENGINEER approval.
3.2 Pre-Construction Survey
Prior to any construction activities, the CONTRACTOR shall carry out a pre-construction
survey to stake the pipeline centreline and define the Right-of-Way (ROW) by stakes placed
at locations where they shall not be disturbed and from where the boundary of the ROW can
be determined.
CONTRACTOR shall stake the entire pipeline route(s) as per the data available on the
alignment drawing(s) (typical and detail), in compliance with a Procedure/Method Statement,
to be submitted to and approved by AD WEA/End users/ENGINEER.
The construction survey control shall be staked at a distance of 100 meters maximum from
each other. The staking shall be based on the markers set along the pipeline route and
construction drawings. CONTRACTOR shall establish a reference point 25 meters offset from
pipeline centreline.
The final pipeline alignment shall be subject to approval of ADWEA/End users/ENGINEER.
3.3 Right-of-Way (ROW)
The ROW shall have the dimensions indicated on (typical) drawings approved by
ADWEA/End users/ENGINEER. The pipeline shall be located at the centre of the ROW,
unless indicated otherwise.
CONTRACTOR shall co-ordinate with all local Authorities and utility owners to obtain the
approval for the ROW.
Prior to any cleaning operation, the CONTRACTOR shall make himself familiar with all
provisions on the land secured by and shall use his best endeavours to comply with such
provisions and to avoid any damage to property, including other pipeline facilities on or
adjacent to the ROW.
Prior to the commencement of any construction activities in an area, the CONTRACTOR shall
locate and identify all existing buried facilities, such as cables, pipelines, water mains, sewers,
etc., including those not shown on the drawings, crossed or at close proximity with the
pipeline, by contact with relevant Authorities, carrying out appropriate surveys and exposing
them by hand excavation, unless exempted in writing by ADWEA/End users/ENGINEER.
Once located, the underground f acilities crossed by the pipeline route or running parallel to it,
within the ROW, shall be clearly marked by methods approved by ADWEA/End
users/ENGINEER.
CONTRACTOR shall submit for approval by a detailed proposal for precautions to be taken
for avoiding or preventing damage to existing pipelines, electrical lines and cables, fences,
Client ADWEA

roads, drainage, and any other existing above or below ground structures or property of
whatsoever nature adjacent to or crossing the pipeline being constructed.
CONTRACTOR shall note that the cutting or removal of trees and plantation is strictly
prohibited.
All work carried out in the vicinity of existing pipelines and associated installations shall be
performed only after the issue of a valid permit and shall comply with safety precautions.
3.4 Crossings
Crossing of roads, buried services, etc. with equipment and/or personnel shall only be
permitted after the CONTRACTOR has obtained written approval from the authorities having
jurisdiction.
It shall be CONTRACTOR's responsibility to acquaint himself with all relevant requirements

and regulations of authorities and governmental bodies having jurisdiction over highways,
roads, pipelines, cables and other services on the Right-of-Way or crossing the Right-of-Way
and to obtain their approval in writing and all necessary permits before commencing work.
Notwithstanding the provision of drawings and specifications by ADWEA/End
users/Engineer's, it shall also be CONTRACTOR's responsibility to ensure that the Work is
performed to the requirements and specifications of the relevant authorities. In the event that
the requirements and specifications of the authorities are more stringent than ADWEA/End
users/Engineer's, then the authorities' requirements shall be prevail.
Highways, Main-Roads and their verges shall not be used for loading, unloading or stacking
of materials and/or equipment. For secondary roads, such loading/unloading is permitted only
after prior approval from the concerned authorities. CONTRACTOR shall not close or divert
roads without prior approval from ADWEA/End users/Engineer's and the concerned
authorities. CONTRACTOR shall never unnecessarily hamper the users of the roads.
The diversion specifications, if required, shall conform to the approval of relevant authorities
and in accordance with the specifications required by them.
For construction methods of crossings reference is made to section 3.11.
3.5 Clearing, Grading and Backfilling of ROW
3.5.1 General
During the preparation of the ROW , the CONTRACTOR shall grade the ROW to provide
access to the pipeline during construction.
CONTRACTOR shall grade the ROW to remove sharp, high points, to minimise bending and
to maximise laying within the limits permissible for elastic bending.
Where the construction ROW passes through or along roads, tracks, pole lines, plantations or
any other improved or confined areas, CONTRACTOR shall grade only the width of the ROW
Client ADWEA

necessary for digging the pipeline trench. In areas where the construction activities require a
greater width, CONTRACTOR shall obtain prior approval from ADWEA/End User/Engineer.
CONTRACTOR shall establish any additional survey monuments required and shall maintain
and preserve survey monuments (already staked on ground) such as Bench Marks and
Intersection/Turning Points until the construction is completed. In case of any missing bench
marks, CONTRACTOR shall re-establish them, as directed by ADWEA/End users/Engineer's,
to carry out levelling work during laying or as-built survey of the pipeline.
CONTRACTOR shall carry out all survey and leveling of line and grades including as-built
survey necessary to complete the work and shall be responsible for the accuracy of such
survey and grades.
The ROW for all the pipelines shall be staked by the CONTRACTOR so as to be able to
define ROW boundary for purposes of clearing, grading and backfilling. The stakes shall be
installed and the continuity of the pipeline centreline and ROW limits shall be maintained
throughout construction.
CONTRACTOR shall install distinct markers locating and indicating special points, such as
but not limited to contract limits, warning notices, presence of buried structures, obstacle
crossings, change of wall thickness including corresponding chainage, etc.
Markers shall be of a sufficient height and of material and type approved by ADWEA/End
users/Engineer's so as to serve their purpose. CONTRACTOR shall be responsible for the
maintenance and replacement of the reference line markers until the permanent pipeline
markers are placed and the as-built drawings are submitted and approved.
3.5.2 Fences and Barriers
On completion of construction the CONTRACTOR shall reinstate any damaged or relocated

fencing on camel compounds, pipeline corridors, and property boundaries to their original
condition. CONTRACTOR shall be liable for any damage, claims or actions arising from
breaches made in existing fences.
CONTRACTOR shall install suitable warning trench mesh on either side of ROW where it is
essential to ensure safety and non-interference, especially in industrial or in inhabited areas,
etc., or in the proximity of roads or other installations, or where directed by , supported by
suitable approved steel supports.
The CONTRACTOR shall provide and install heavy grade concrete barriers at any location
where traffic might accidentally encroach on the construction.
Fencing and barriers shall be continuously maintained.
The CONTRACTOR shall note that motor trucks cross a number of the tracks that pass over
(and obstruct) the ROW and that provision (detours) shall be provided for these activities to
continue without interruption. Permits from the Author ities will be necessary even for any brief
closures of these tracks.
Client ADWEA

3.5.3 Removal of Debris
The CONTRACTOR shall remove all debris, timber, dislodged and similar material, rock
particles, etc., from the ROW and dispose of it in a manner and method satisfactory to
ADWEA/End users/Engineer's and Government Authorities having jurisdiction over the areas
concerned. CONTRACTOR shall be responsible for all surplus material disposals, if any,
arising out of clearing and grading operations.
3.5.4 Grading of ROW
The construction of the access roads in the ROW shall be carried out in conjunction with the
clearing and grading of the ROW. After clearing the ROW and when grading has been
performed so as to allow passage of loaded trucks and equipment without undue wear and
tear thereon, the CONTRACTOR may commence his scheduled work. CONTRACTOR will
have to grade sand dunes to allow vehicle access, safe laying of the pipeline within its elastic
limit, and excavation of rock wherever encountered. Fill material shall be installed on the
ROW as needed for vehicle access. The CONTRACTOR shall grade and construct the ROW
so that the trench is excavated in undisturbed ground.
CONTRACTOR shall make necessary arrangements such as ramps, temporary bridges, etc.,
for crossing them with men and machinery. This shall be accomplished in such a way as to
permit their continued vehicular and other traffic use and to preserve the banks and structure
of the crossings. No existing crossings shall be filled or otherw ise obstructed without approval
of the Person or Authority having effective control over such crossings. CONTRACTOR shall
furnish to ADWEA/End users/Engineer's such notices received, in original, prior to
commencing the work.
3.5.5 Restricted ROW
When the ROW passes through any plantations, public roads, electric cables, buried services
of whatsoever nature, or other confined areas, only the minimum ROW necessary for the
actual excavation of the trench and construction of the pipeline and maintenance road shall
be used. CONTRACTOR shall perform the work at such places in such a way so as not to
cause damage to any tree or plantation, and shall ensure that there is no damage to any tree
or plantation.
When the pipeline crosses any existing surface or sub-surface pipeline, service property,
roads, cables, and other such items, only Right-of-Way (ROW) required for construction of the
pipeline and maintenance road shall be used. CONTRACTOR shall perform work in such a
manner as to not interrupt the operation of the existing pipeline / service or damage the
existing pipeline/service.
The CONTRACTOR shall not be entitled to extra compensation for any hardship and/or
increased costs caused by the construction areas being adjacent to or in sand dunes or other
difficult terrain or across roads, berms, flooded areas, communication structures, wires,
cables, other pipelines, power poles, plantations, farms or other obstacles, which may
physically restrict or limit the use of the ROW provided. It is understood that the
CONTRACTOR has recognised such restrictive features of the ROW and has included an
Client ADWEA

allowance for any necessary drilling costs or other construction techniques necessary in
restricted areas or under any plantation and highways in the Agreement Price.
3.5.6 ROW Dama ges
The CONTRACTOR shall be liable for any and all remedial work for damages to existing
pipelines and associated equipment, tracks, roads, highways, and all other utilities, property
of whatsoever nature, etc., caused by him. The CONTRACTOR shall agree to perform such
remedial work as and when required by this Specification, and/or by ADWEA/End
users/Engineer's.
3.5.7 Provisions of Detours
At locations where any part of the work is routed along, over, under or across tracks, roads or
highways, the CONTRACTOR shall, with no extra compensation, provide and maintain
detours, temporary bridges and road controls including warning lights as may be required by
the concerned Authorities.
Public travel shall not be unnecessarily inconvenienced nor shall it be wholly obstructed at
any time.
CONTRACTOR shall supply watchmen at any location where safety and work operations
justify their use, or where directed by ADWEA/End users/Engineer's, and shall maintain
detours and shall supply and maintain lanterns, barricades, signs, wherever necessary, to
fully protect the public and facilitate the smooth runni ng of the contract.
3.5.8 ROW in Rough and Rocky Terrain
ROW in rough and rocky terrain that occurs at certain locations shall be prepared by
CONTRACTOR, with the use of special equipment as necessary.
Wherever rocky terrain is encountered, grading and excavation to prepare ROW shall be
carried out by ripping, drilling, wedging, chiseling using jack hammers or rock breakers, or by
other recognised methods approved by . Blasting will not be allowed. CONTRACTOR shall
only use methods for grading/excavation in rock as approved by ADWEA/End
users/Engineer's.
3.5.9 ROW in Sand Dune and Sandy Areas
The ROW in sand dune and sandy areas shall be graded by the CONTRACTOR in
compliance with the relevant drawings and shall be approved by ADWEA/End
users/Engineer's. The profile of the graded ROW shall generally follow the profile of the
natural terrain with some minor alterations to enable proper construction of the pipeline and
ensure safe bending and laying of the pipeline. While grading, any necessary cutting of high
dunes shall be performed. The cut material shall be generally spread on the sides of the
ROW and filling of low areas shall be minimised. Trenching will follow the general profile of
the ROW as per the cover requirements. Localised sand dunes along the pipeline alignment
shall be removed by CONTRACTOR as a part of his scope of work while preparing ROW.
Client ADWEA

3.5.10 ROW in Sabkha Area
The ROW in Sabkha areas shall be constructed with gatch material, which shall be
consolidated by compaction. The type of fill material to be used by CONTRACTOR shall be
approved by ADWEA/End users/Engineer's. The CONTRACTOR shall provide a clear ROW
after consolidation, as indicated on the drawings. shall approve the section of the ROW in
Sabkha area as construction activities proceed.
3.5.11 Gatch Material for ROW
Gatch material to be used for preparing ROW, or for stabilisation of ROW by CONTRACTOR
shall be granular dry soil material with high level of cementation content, such as gypsum or
clay which when watered, mixed and compacted, gives a firm and solid mass of material. The
compacted gatch shall not contain loose patches of soil and shall not break nor erode during
normal use and environmental conditions. CONTRACTOR shall arrange to locate the source
of gatch material and obtain ADWEA/End users/Engineer's approval for the use of the gatch
material. The gatch material characteristics as well as the source of the subject gatch need
approval prior to hauling the gatch material to the working site. CONTRACTOR shall also
obtain ADWEA/End users/Engineer's approval from concerned authorities for mining of gatch
from source.
Gatch, at the optimum moisture content, placed in the ROW, shall be consolidated by
compaction as specified and requires ADWEA/End users/Engineer's approval. The gatch
material shall be wetted, rammed and compacted. The required density, not less than 95
percent standard proctor density, shall be obtained by compaction in layers of 200 millimetres
by suitable means. Moreover water shall be sprayed on the placed material as required prior
to compaction to maintain the optimum moi sture content. Note that the requi red density of the
compacted bund shall not be less than 82 percent standard proctor density.
3.5.12 Minor Route Deviations
CONTRACTOR shall carry out, as part of his scope of work, any local realignment of pipeline
route/profile and/or design modification as required necessitated by the presence of any
underground structure, service or utility found during excavation.
3.6 Handling, Hauling, Stringing and Storage
3.6.1 Pipe Material
3.6.1.1 Receipt of Pipe Material
CONTRACTOR shall supply pipe materials as specified in the relevant Project Material
Specification(s) at a designated area, subject to ADWEA/End users/Engineer's approval.
Prior to taking delivery from SUPPLIER, CONTRACTOR shall examine the pipes and satisfy
himself about the condition of the pipe. After taking delivery of the pipes, CONTRACTOR
shall be responsible for their care and custody and for any repairs to any damage.
Transportation of pipe to the construction site is the CONTRACTORS' responsibility.
Client ADWEA

Pipes which have been found damaged at the time of taking over, shall be marked and
stacked separately and shall only be transported to the site after the defects have been
repaired or eliminated, unless otherwise agreed with ADWEA/End users/Engineer's.
CONTRACTOR shall be fully responsible for arranging and paying for storage areas and
method of storage shall be as approved by ADWEA/End users/Engineer's.
3.6.1.2 Handling of Pipe
The CONTRACTOR shall be responsible for handling, hauling, stockpiling, storage and
stringing the pipe materials. Pipes shall be supplied fitted with end caps, which shall remain in
place until the pipes will be joined together.
The CONTRACTOR shall be responsible for providing suitable trucks and equipment in
sufficient quantity to transport the line pipe in such a manner that prevents damage.
Pipe, bends and other fittings shall be stocked, chocked and padded, and secured in position
during transportation and during storage at pipe dumps or stringing in a manner approved by
ADWEA/End users/ENGINEER. If pipes are supplied in bundles or on pallets, they shall
remain so packaged until they are delivered to the location of installation on site.
Care and attention should always be applied when handling pipes, not only for the protection
of the pipe materials but also for the safety of the handling personnel. Where possible, pipes
should be unloaded individually by hand. There are occasions where pipes may already be
bundled in frames, in this case proper lifting equipment shall be used.
Pipes shall never be dropped onto hard or uneven surfaces. Pipes shall never be thrown from
vehicles or be dragged or rolled along the ground.
Where pipe weights exceed practical personnel handling then rope or web slings shall be
used with mechanical lifting equipment. Metal chains, hooks or cables shall never be used.
Pipes shall be transported on vehicles with a flat bed and free from sharp edges or
protrusions.
Pipes shall generally be supported over their full length and not overhang by more than one
metre.
Pipes shall be stored on a flat even surface able to withstand the weight of both pipes and
lifting equipment.
Different sizes of HDPE pipes should be stored and/or transported separately. Where this is
not possible, the larger diameter and/or thicker wall pipe shall be loaded first having side
supports at no more than 1.5 m intervals. All supports shall be free from sharp edges.
Pipes shall be kept away from lubricating or hydraulic oils, gasoline, solvents or other
materials that may be deleterious.
HDPE pipe materials shall be stored under cover, protected from direct sunlight and ensuring
good ventilation. Storage in containers is not recommended.
Client ADWEA

3.6.1.3 Damaged Pipes
After the pipes have been strung on the ROW, they shall be inspected by the representatives
of CONTRACTOR and ADWEA/End users/Engineer's at the same time, and any defective
pipes shall be rectified or rejected as directed by ADWEA/End users/Engineer's The
CONTRACTOR shall supply new pipes as per applicable specification(s) as replacement for
any rejected pipes including any pipes damaged to the extent that these cannot be used.
3.6.1.4 Care of Pipe
The CONTRACTOR shall lay out and measure the pipe so that the number of cut off pieces,
less than 1.5 met ers long, is held to a minimum.
3.6.1.5 Hauling and Stringing of Pipe
Pipe shall be unloaded from the stringing trucks and lowered by hand, or by means of suitable
equipment approved by ADWEA/End users/Engineer's onto pipe supports, placed on the
ground. Chains, cables or hooks inserted into the pipe ends shall not be used.
Pipes shall be strung alongside the trench on supports properly spaced with the pipe at least
100 mm clear of the ground. The trench is to be completely excavated, the area cleared of all
debris, and the requisite bedding and base padding stockpiled, before stringing of the pipes.
However the CONTRACTOR shall note and make allowance for sand drift into the trench in
sandy areas, especially where sand dunes exist.
The pipes shall be strung parallel to the ditch at a suitable and constant distance from the
centre line of the ditch. The stringing of the ROW shall be done in such a manner that will not
put the pipe at risk and so as to cause the least interference with the normal use of access by
trucks, etc. Gaps shall be left at intervals or wherever requested by other users to permit the
passage for traffic or equipment across the ROW or along public roads or highways. Pipe
stringing shall be done in such a manner as not to cause a hazard or possible damage by
traffic.
All pipe strung on the ROW shall be supported in such a manner that the pipe is free from
contact with the ground at all times. Pipe ends shall be protected with plastic end covers to
prevent sand from entering the pipe while the pipes are strung al ong the ROW.
3.6.2 Care of Other Materials and Properties
Materials supplied by the CONTRACTOR or free issued by ADWEA shall be stored in a

secure and sheltered place and such material shall not be strung on the ROW but shall be
transported along the line in covered conveyances for use when needed. CONTRACTOR
shall be fully responsible for providing and paying for storage area and sheds.
In case of any delays/interruptions in handing over of ADWEA supplied materials,

CONTRACTOR shall be fully responsible for stopping and rearranging means of
transportation at no extra cost to ADWEA.
Client ADWEA

The materials mentioned above shall during loading, unloading, storage and use always be
handled to prevent any damage, deterioration, adulteration or dispersion and any health
hazard to human beings or livestock or any other damage. When supplied in containers and
envelopes, they shall not be dropped or thrown, or removed by means of hooks during the
handling operations and the containers shall only be disposed of in a manner authorised by
ADWEA/End users/Engineer's.
During unloading, transport and utilisation, any contact with water, hydrocarbons, chemicals,
mud, earth, dust, crushed stone and any other foreign material shall be carefully avoided.
CONTRACTOR shall strictly comply with MANUFACTURER's instructions regarding handling
and storage, and in particular the temperature of volatile materials which are susceptible to
change in properties and primary characteristics due to unsuitable storage.
For materials liable to corrosion while in storage, CONTRACTOR shall exercise proper care
including application of non-hydrocarbon grease or MANUFACTURER-recommended
treatment to areas/surfaces susceptible to rusting, or the provision of air-conditioning for
temperature/humidity control.
Flammable materials shall be stored in special safe storage locations.
3.7 Trenching
3.7.1 Excavation
CONTRACTOR shall excavate the pipeline trench on the surveyed route as staked and to the
design profile.
CONTRACTOR shall not start the ditching operations until the pipeline centreline has been
approved by ADWEA/End users/Engineer's.
CONTRACTOR shall excavate the pipeline trench within the cleared and graded ROW using
any method approved by ADWEA/End users/Engineer's. Care shall be exercised to see that
fresh material recovered from trenching operations, intended to be used for backfilling over
the pipe in the trench or at the berms, is not mixed with loose debris or with foreign or rejected
material, required to be removed from site.
3.7.2 Normal Cover and Trench Dimensions
Normally, the trench shall be excavated to a minimum width so as to provide, on both sides of
the installed pipeline, a clearance as specified in the typical drawings and to a depth s ufficient
to provide the minimum covers specified below. The dimensions as given herein and in the
typical drawings shall govern except as otherwise specified or detailed on the detail pipeline
drawings. The cover shall be measured from the top of the pipe, after it has been laid in the
trench or placed on the formation level, to the level of the original ground or graded surface
where such surface is lower than the original ground level.
Client ADWEA

3.7.3 Minimum Cover Requirements for Pipe
Normal Terrain and Sand Dunes 1.0 m (min)
Sabkha Area (On Prepared ROW ) 1.5 m (min.)
Track Crossings 2.0 m (min.)
City/Town/Inhabited Area 1.0 m (min.)
Metalled, Paved and Rig Road Crossings 2.0 m (min.)
Wadi areas 3.0 m (min.)
3.7.4 Extra Depth and Clearances
CONTRACTOR shall excavate to additional depth where the pipeline approaches and
crosses other pipelines, sewers, drain pipes, water mains, telephone conduits, and other
underground structures to facilitate the use of elastic bends. The pipeline shall be laid with at
least 1 meter free clearance under the obstacle or as specified on the drawings. If greater
minimum distances are required by Authorities having jurisdiction, those distances shall be
maintained.
Where the pipeline crosses areas whose easements specifically require greater than normal
depths of cover, the trench shall be excavated to extra depth as required, including any
necessary "lead in" and "lead out".
3.7.5 Protection of Underground Utilities and Special Methods
As the general route follows existing pipelines and/or cables, the CONTRACTOR shall apply
all methods to ensure safety and protection of these existing facilities. Close co-ordination
shall be undertaken by CONTRACTOR with relevant Authorities during all construction
phases and particularly during excavation work.
Details of underground utilities, as available, will generally be indicated on the drawings.

However, CONTRACTOR shall make all reasonable efforts to obtain plans and full details of
all existing and planned underground services from the relevant Local Authorities and Facility
Operators. The CONTRACTOR shall follow these plans closely at all times during the
performance of the work. CONTRACTOR shall be however responsible for locating and
protecting all underground lines and structures, whether shown on the drawings or not. The
CONTRACTOR shall use pipeline locators and any other necessary means including manual
excavation for locating all lines, utilities and substructures as part of his Scope of Work.
The use of trenching machine/back hoe may result in damage to property and/or subsurface
structures likely to be encountered during excavation, and CONTRACTOR shall only
excavate the trench within 1.5m of such structures manually at no extra cost in compliance
with ADWEA/End users/Engineer's Procedures.
Client ADWEA

Where the pipeline crosses other underground utilities/structures, the CONTRACTOR shall
first manually excavate and expose such utilities/structures, and clearly record their details
and location on as-built drawings i.e. types, diameter, horizontal and vertical location and
angle relative to the new pipeline.
Temporary underpinning or any other supports and protective devices necessary to protect
the structure from damage shall be provided by the CONTRACTOR at his own cost.
CONTRACTOR shall support crossed structures/utilities above and/or below ground.
If, despite all precautions, any damage should occur to any structures/utilities, etc., the
Owner/Authority concerned shall immediately be contacted by the CONTRACTOR and
repairs shall be completed at the CONTRACTOR'S expense. The repairs shall be completed
under the direction and to the satisfaction of ADWEA/End users/Engineer's and the
Owner/Authority. If CONTRACTOR fails to complete the repairs within a time agreed upon,
reserves the right to have the repair(s) completed by others at the cost of the CONTRACTOR.
CONTRACTOR shall also arrange and provide as part of his Scope of Work all permanent
protection measures to cables, pipelines etc. being crossed, as required by Authorities having
jurisdiction. Such works shall not be limited to providing additional coating, sleeving,
concreting, etc.
If it is deemed necessary, CONTRACTOR shall, subject to clearance of all the statutory

authorities concerned, arrange to re-route the utility lines. Subject to actual agreement, the re-
routing shall be done by the CONTRACTOR (or on reimbursable basis by the
CONTRACTOR) by an approved sub-contractor designated by the statutory authority.
3.7.6 Grading, Padding and Finish of Trench or Formation
The trench or formation shall be cut or made to a grade that shall provide a firm, uniform and
continuous support for the pipe, allowing for any necessary bedding and padding. Bends shall
be made in the pipe at significant changes in grade of the trench. ADWEA/End
users/Engineer's reserves the right to set the grade of the trench and locate the bends if so
desired, in which case CONTRACTOR shall excavate at no extra cost the trench so that
changes of grade will be by elastic bends, or bend the pipe to achieve changes of grade.
ADWEA/End users/Engineer's desires to reduce to a minimum the required number of bends
to lay the pipe to conform to the general contour of the ground and maintain the minimum
cover. This can be accomplished by cutting the trench slightly deeper at the crest of ridges
and by gradually deepening the trench in approaches to road crossings and small water
courses, if any.
ADWEA/End users/Engineer's intends that there will be a minimum of hand grading of the
trench bottom. To achieve this, CONTRACTOR shall dig as square a bottom of the trench as
possible with his equipment. CONTRACTOR shall do such hand work in the trench as is
necessary to ensure the bottom of t he trench is free of loose rock and hard lumps of material.
In all cases where rock or gravel or hard material is encountered in the bottom of the trench or
on filled ROW (where the pipeline is laid on filled ROW), ADWEA/End users/Engineer's will
decide the exact extent of bedding that shall be required. The thickness of the compacted
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bedding shall not be less than 200 mm. In those areas that are to be bedded, the trench shall
be at least 200 mm deeper than otherwise required, and evenly and sufficiently bedded to
keep the pipe, when in place, at least 200 mm above bott om of excavated trench.
Acceptable bedding shall be placed under the pipeline before its installation, and padding
around it after installation to establish at both sides and on top of the pipe a permanent layer
of bedding. The thickness of compacted bedding around the pipe corrosion coating shall be at
least 200 mm. Bedding and padding materials that are approved by shall be sand containing
no gravel, rock or lumps of hard material or any other material that may be deleterious to the
pipe coating. On slopes, trench breakers shall be installed to prevent the migration of bedding
and padding.
3.7.7 Trenching in Sand Dunes
Where the pipeline is to be laid in sand dunes, the trench shall be cut so that ade quate trench
bottom width is obtained in compliance with the applicable drawings.
3.7.8 Trench Crossings
CONTRACTOR shall, in all cases where the trench has been cut across access roads/tracks
etc., install a by-pass track or substantial temporary bridge work to the full width of the
roads/tracks, of adequate strength, properl y constructed to ensure the safety of the public and
to allow passage of normal traffic with minimum inconvenience and interruption. The
CONTRACTOR may also propose to ADWEA/End users/Engineer's a suitable alternate
route. However, this shall have no cost impact to ADWEA.
Wherever deemed necessary by ADWEA/End users/Engineer's, the CONTRACTOR shall

arrange to complete the trenching, laying and backfilling of such crossings and to remove the
temporary bridging before the end of the regular work day in order to minimise the hazard to
night traffic.
The CONTRACTOR shall obtain the written permission of the appropriate authorities, before
commencing work and shall ensure that all regulations and requirements of the authority
having jurisdiction over such tracks are complied with. Proper warning signs shall be placed
and maintained while such crossings are open. If such crossings are open at night, the
CONTRACTOR shall provide adequate number of warning lights of a type approved by
ADWEA/End users/Engineer's and the responsible authorities.
3.7.9 Protection of Trench And Auger Pits
CONTRACTOR shall keep the trench/pits in good condition until the pipe is laid and until
backfill takes place. No claim is to be made to ADWEA/End users/Engineer's by the
CONTRACTOR for reason of the trenches collapse either before or after the pipe is laid. All
materials necessary to shore the trenches and pits in order to prevent collapse and for safety
are to be furnished, installed and subsequently removed by CONTRACTOR without any
additional compensation.
Client ADWEA

In the circumstance of ground water being encountered, the CONTRACTOR shall provide
adequately-sized dewatering equipment, shoring and any other equipment and materials
required to excavate the trenches and pits. The CONTRACTOR shall install the pipe and
backfill the trenches and pits in accordance with these Specifications and drawings. All
trenches and pits shall be excavated in dry conditions and kept dry during all phases of work
until completion of backfilling.
Where the pipeline is laid close to any existing pipelines or services, the requirement of the
Authority/Agency having jurisdiction over the existing pipeline/service regarding safety,
additional protection, etc. shall be complied with by CONTRACTOR as a part of his scope of
work.
3.8 Pipe Laying and Jointing
3.8.1 Pipe Laying
Pipe shall be laid to a minimum depth of cover as specified in paragraph 3.7.3.
Laying of the pipe and making of connections shall be undertaken in a dry trench.
During pipe laying operations the ends of the pipe shall remain sealed by pipe end caps, until
immediately prior to jointing.
Pipe handling shall be in accordance with the requirements of Section 3.6 above. Exposed
PE pipe shall be properly supported and protected from UV light, environmental attack and
mechanical damage.
The induction of stresses in the pipe or in joints during installation shall be avoided. The
following precautions shall be taken :
• Prevent the pi pe from being damaged by contact with sharp materials during installation.
• If the PE pipe is laid by drag, care shall be taken that the drag force is not exceeding the
allowable force as specified by the MANUFACTURER or SUPPLIER of the pipe material.
• Comply with the minimum allowable bending radii specified in paragraph 3.8.2.
• Ensure that the pipe is uniformly supported.
• Ensure that the trench is in compliance with the requirements of section 3.7 above, and
that proper bedding and padding material is used where required.
• Ensure that no stone or rock impingement exists at the pipe to soil interface.
• If the pipe is laid in a sleeve, ensure that the sleeve ends are fitted in such way that no
stress or cutting effect can be transmitted to the PE carrier pipe.
Client ADWEA

3.8.2 Minimum Allowable Elastic Bending Radius
Where bending of PE pipes is unavoidable, pipes may be curved elastically to a minimum

radius as recommended by the manufacturer. In general, a smaller radius shall require a
formed bend or elbow. In the event of the manufacturer providing no recommendation the
minimum bend radius shall not be less than 20 times the pipe OD. No electrofusion or
mechanical joints should be incorporated in the sections of pipework which are to be bent.
Instead a formed bend or elbow should be welded in the pipeline in order to prevent
excessive stress.
3.8.3 PE Pipe Jointing
3.8.3.1 General
The CONTRACTOR shall employ the services of a specialist SUBCONTRACTOR to perform

all of the following jointing techniques to create PE pressure pipe systems. The specialist
SUBCONTRACTOR shall be subject to ADWEA/End users/Engineer's approval.
• To joint lengths of straight pipe and incorporate fittings such as bends, equal tees and
reducers; automati c butt fusion joining procedure shall be used.
• To joint PE pipes to metal pipes and to valves; restrained transition fittings and stub
flanges shall be used.
• To install off-takes or connections to existing lines, and on locations indicated and

approved by ADWEA/End users/Engineer's; electrofusion fittings may be used.
3.8.3.2 Method Statement
A detailed Method Statement (MS) for PE pipe jointing shall be prepared by the
CONTRACTOR, and submitted to ADWEA/End users/Engineer's for approval. This MS shall
include details of how the work will be performed to ensure compliance with all requirements
and recommendations of the MANUFACTURER or SUPPLIER of the PE pipe material and of
this Specification.
This MS shall ensure that all fusion joints are of high integrity and shall include, but not by
limitation :
• Procedures for the operation, maintenance, periodic inspection and testing of fusion
tools and equipment.
• A programme of update training for PE jointers, including certification and re-certification

of personnel to ensure competence.
• Procedures for joint preparation, indicating method and degree of cutting, cleaning,
drying, scraping, alignment, support, etc. of the pipe ends to be joined.
• Jointing procedures, specifying the equipment and tools as well as all relevant
parameters (temperatures, pressures, heating time, cooling down time, joint fusion, etc.)
and control of the jointing operations.
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• Inspection and testing procedures and acceptance criteria together with proposals for
independent inspection and testing on welds on a regular basis. As a minimum, 1 % of
all welds shall be tested on a regular basis and approved by a third party testing body.
The testing shall involve both testing of random welded joints and material
characteristics performed by an independent test laboratory All costs associated with the
testing, together with any consequent rectification of faults and retesting shall be borne
by the contractor.
• QA/QC procedures
• All safety precautions and procedures.
3.8.3.3 Electrofusion
Barcode labelled or auto recognition electrofusion jointing shall be used and only fittings
incorporating fusion indicators shall be acceptable.
The equipment used for joint construction shall provide fusion data in the form of a print out
specific to each joint, which shall include each joint's unique joint number. These print outs
shall form part of the as built records.
The electrofusion control box shall deliver the correct fusion parameters to the electrofusion
fitting. The power generator shall provide the power requirements of the control box, taking
into account the electrical characteristics of the control box.
Positioning tools including suitable mains alignment clamps shall be used for all types of
electrofusion systems to minimise misalignment and prevent movement during the fusion and
cooling cycle of the joint. A suitable shelter and mechani cal scraper will be used for all jointing
operations.
All pipework to be washed prior to commencement to remove any contamination. After which,
a uniform and efficient scrape shall then be performed to remove the oxidized surface to a
depth between 0.2 and 0.4mm. This shall be achieved using a mechanical scraper which is
capable of cutting a continuous strip of swarf over more than the insertion length of the
coupler and round the pipe.
Only after preparation and scraping of the pipe end should the fitting shall be removed from
its packaging and immediately inserted over the pipe end.
3.8.3.4 Electrofusion Inspection
A dot or line shall be initially marked on the pipe or spigot end to determine/confirm the depth
of penetration. If a clamping/scraping tool is used which indicates the depth of penetration,
then the marking requirement no longer applies. Each pipe or spigot end shall penetrate
completely its relevant part of the electro-socket.
Melt from the fusion process shall not exude outside the confines of the fitting. If this occurs
the joint shall be removed immediately.
Client ADWEA

If the fitting is designed with fusion indicators, after the fusion they shall be in a position
complying with the fitting MANUFACTURER's instructions.
Alignment clamps shall not be removed before the appropriate cooling time has elapsed.
Abnormal displacement of the electric wire coils shall not occur. This shall be checked prior
to commencement of fusion.
3.8.3.5 Butt fusion
The equipment employed shall be fully automatic and shall provide fusion data in the form of
a print out specific to each joint, which shall include each joint's unique joint number. These
print outs shall form part of the as laid records.
All external beads shall be removed with an approved tool and inspected for defects.
Each bead shall be numbered with its corresponding joint number clearly displayed.
Removed beads shall be retained for inspection by ADWEA/End users/Engineer's.
The Method Statement for butt fusion systems, submitted to ADWEA/END users/ENGINEER
for approval, shall include the following :
§ Only pipes and fittings of the same size, SDR and material are to be butt fusion welded.
§ A dummy joint shall be made at the start of each welding session using pipe off cuts of
the same size, material and SDR as the pipe being installed. The normal trimming, bead-
up and full heat soak cycles will be adhered to. For pipe sizes greater than 180mm two
dummy welds will be made. If the pipe size is changed during the day, if the heater plate
is allowed to cool below 180°C or if maintenance of the butt fusion equipment is carried
out then a new dummy weld/s shall be performed.
• Before the first joint of the day, or any change of pipe size and after cleaning or
maintenance of the butt fusion equipment, the hotplate shall be placed into the machine
and the pipe brought up to form a weld bead. This joint shall not be fused. The hotplate
shall be removed and the melt allowed to cool for at least 10 minutes and the pipe
trimmed back to remove the bead and the heat zone. Normal jointing will then continue.
3.8.3.6 Butt Fusion Inspection
All butt fusions shall be inspected and approved in accordance with the following criteria :
• The gap between the two single beads shall not be below the fusion surface.
• The displacement between the fused pipes must not exceed 10% of the pipe wall
thickness.
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• The difference between two single beads shall not exceed 10% of the double bead
width.
• No signs of damage (such as scratches or deep impressions caused by clamps) shall be

visible on either side of the fusion.
• A bead gauge shall be used to assess the bead width. Bead widths shall be within the
ranges specified in Table 3.1 and shall be of uniform appearance.
• The underside of the bead shall be examined and the bead inspected for lack of fusion,
contamination, holes, offsets and melt damage.
• Beads should be solid and rounded with a broad root. Hollow beads with thin root and
curled appearance may have been formed with excessive pressure or no heat soak.
• A bead bend back test, shall be conducted where the bead is bent, around the finger,
every few inches and the bead inspected for slit defects. This test will highlight fine
contamination from the heating plate. Any joints found to be contaminated shall be cut
out and a new joint made; the failed joint shall be delivered to .
• Records of all tests and inspections shall be maintained by the CONTRACTOR and
made available for review and approval by ADWEA/End users/Engineer's.
Table 3.1 – Bead Width
Min Wall Thickness Width of Bead

mm mm
10 10 - 17
16 11 - 18
22 15 - 24
28 17 - 26
32 18 - 27
45 20 - 29
57 23 - 32
Note: Intermediate wall thickness shall be taken as the nearest lower wall thickness.
3.9 Backfilling
3.9.1 General
No backfilling shall be performed until the pipe and appurtenances are at the proper
alignment and depth to provide the required cover. Before any backfilling is commenced it
shall be the CONTRACTOR's responsibility to first secure the approval of ADWEA/End
users/ENGINEER. If any backfilling is done without ADWEA/End users/Engineer's approval,
shall have the right to requi re removal of backfill for examination. The cost of such uncovering
and re-backfilling shall be borne by the CONTRACTOR.
Client ADWEA

Subject to compliance with the specifications, the backfilling operation shall follow as closely
as practical to the lowering-in of the pipeline, so as to securely position the pipe in the ground
and to prevent damages due to exposure of the pipe surface to temperature or weather. A
maximum of one hour between lowering in and backfilling is considered acceptable. The
backfill shall be maintained by CONTRACTOR against washouts, etc., until the completion
and final acceptance of the work by ADWEA/End users/Engineer's.
3.9.2 Select Backfill Materials and Padding
Hard materials like gravel, rock, etc. shall not be backfilled directly on the pipe. When such
materials are encountered at the time of trench excavation, ADWEA/End users/Engineer's
shall decide and authorise in writing the extent of trench padding required. CONTRACTOR
shall accordingly provide necessary padding.
In areas designated by ADWEA/End users/Engineer's sufficient sand shall be placed under,

around and over the pipe to form protective padding or cushion extending to a di stance of 200
mm around and above the pipe in a manner approved by ADWEA/End users/Engineer's.
Backfill material shall be free of any rock or other deleterious material.
Material for normal backfill in trench shall not contain any gravel or rock likely to cause
damage to t he pipe surface, and in no instance shall particles exceed 10 mm in dimension.
Loose rock, wherever encountered, may be returned to the trench after the required depth of
select backfill material has been placed subject to the approval of ADWEA/End
users/Engineer's.
On slopes, where directed by ADWEA/End users/Engineer's, trench breakers shall be

installed to prevent the migration of bedding and padding.
3.9.3 Special Treatment of Trench Backfills
Where the trench has been dug through roads/tracks crossings, etc., backfill shall be
thoroughly compacted in compliance with the requirements specified in the Project
Specification for Excavation and Backfill. In certain cases, special compaction methods may
be required by ADWEA/End users/Engineer's. This will have to be followed up by stabilisation
of the surface of the backfill with crushed rock or other suitable material. In all such cases,
CONTRACTOR shall comply with the requirements of the Authorities concerned as a part of
this scope of work.
Any drain tile and/or underground drainage interrupted by the trenching operation shall be
carefully restored and protected, and any damaged portions replaced. In such locations,
backfilling with mechanical equipment shall be prohibited where in the opinion of ADWEA/End
users/Engineer's, damage could result to any service or structure in the vicinity.
3.9.4 Furrows, Terraces, Water Breakers
When backfilling trenches on sloping terrain (slope generally 10 percent or more), and on the
bank of water courses, where backfill may be washed out of the trench, terraces or effective
water breakers across the trench shall be provided by the CONTRACTOR, to divert the flow
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of water away from the trench into normal drainage. In no case is surface drainage to be
diverted into channels other than those followed before the line was laid.
3.9.5 Position of Backfill
It is the requirement of ADWEA/End users/Engineer's to have the ground re-graded to its

original contour after achieving the specified compaction at roads/tracks crossings where
restoration is necessary to assure the safety of the pipeline and the passage of traffic. For
compaction of backfill along the pipeline, conventional mounding over the pipeline after
compaction by wheel/track rolling is acceptable. Mounding shall be suitably trimmed.
The final compaction of the backfill at various location shall be accomplished by tamping or by
running on top of the fill a rubber tyred compacting device approved by ADWEA/End
users/Engineer's or otherwise as directed by ADWEA/End users/ENGINEER.
3.9.6 Stabilisation of Backfill in Sand Dune Areas
The backfill on top of the pipeline shall be stabilised with a five hundred (500) millimetres
layer of gatch material.
3.10 Tying-In
3.10.1 Joining Unconnected Sections
Where sections of the line are to be tied-in after the sections are lowered in and backfilled, the
length of pipeline left unbackfilled shall be kept to a minimum to facilitate the tying-in.
CONTRACTOR shall carry out tie-in jointing, and other associated operations in compliance
with the relevant Specifications herein.
Tie-in joints in restrained sections of the line shall be made when the pipe temperature is at
the minimum, as far as practicable. If necessary to avoid strain in the pipe, sufficient
restrained pipe shall be uncovered to allow slack loops to be held during the line-up and
jointing of the tie-in. Under no circumstances shall the line be left in tension after the tie-in.
Bell holes made to facilitate jointing shall provide adequate clearance to enable the jointer to
exercise normal jointing ability and skill. The lap of the strings at tie-ins shall be at least 2 m
3.10.2 Pups
The CONTRACTOR shall perform his work to minimise the number of pups and shall
progressively carry forward and install same between full lengths of pipe. If pipe is to be
added for tie-in, the minimum length that may be used shall be 1.5 meters and two or more
such pups shall not be jointed together.
3.10.3 Tie-ins After Hydrotest
Tie-ins after hydrotest shall be kept to a minimum, and will be permitted only where approved
by ADWEA/End users/Engineer's.
Client ADWEA

The CONTRACTOR shall ensure prior to hydrostatic testing that sufficient overlap is available
to facilitate tying-in.
3.11 Special Crossings/Road Crossings
3.11.1 General
For general requirements reference is made to paragraph 3.4 above.
3.11.2 Construction Methods
Minor Road (un-metalled) and track crossing shall be uncased and shall be constructed by
open cut method, with a suitable detour provided for road users.
Crossing of metalled and major roads shall be installed by non-disruptive techniques, with a
suitable detour similarly provided if necessary. PE pipes shall be installed in a steel casing
pipe.
In all cases, the CONTRACTOR shall submit to ADWEA/End users/Engineer's the proposals
for the installation of the crossings, the schedule, detail of the methods to be used, the type of
equipment and results of any investigations and surveys. Work on the crossing shall not
commence until the CONTRACTOR's methods and procedures have been approved in
writing. A specific "Crossing Drawing" shall be prepared for each major road crossing.
Construction of crossings shall include the provision of warning signs and barricades and all
necessary clearing and grading, excavating, shoring, de-watering, trenching, boring, welding,
coating, lowering, backfilling, clean up, restoration and any further work required.
Before the installation work of crossings is started, the CONTRACTOR shall provide suitable
trench mesh barricades. Adequate traffic warning signals and/or traffic lights and suitable
diversions shall be provided as directed by ADWEA/End users/Engineer's and local authority.
Actual installation of crossings shall comply with the drawings issued for construction by
CONTRACTOR. CONTRACTOR shall fully investigate all details of the crossing and make all
necessary provisions at the time of construction.
To avoid settlement in open cut crossings, the pipe shall have firm bearing on the bottom of
the trench for a distance of not less than five metres beyond each side of the crossing ROW
limits. This shall be accomplished by compacting the bottom of the trench and after
installation, thoroughly watering the padding and compacting the backfill using methods
approved by ADWEA.
The track sub-surface and surface layers are to be reinstated to the satisfaction of the
relevant authority and in accordance with specification and drawing.
3.11.3 Road Crossings
For the major road crossings and metalled roads where the pipeline is to be laid without open
cut of the road, the CONTRACTOR shall install a steel casing by the thrust bore or use
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directional drilling method as indicated on the drawings. CONTRACTOR may propose
alternate method of installation subject to approval of ADWEA/End users/Engineer's
The carrier pipe shall protrude at least 1 length (joint) into the installation ditch on the opposite
side so that any potentially damaged section of the pipe may be cut. This length can be
increased by ADWEA/End users/Engineer's, depending on the observations made and the
number and kind of damages found on the external pipe surface, without any compensation
to CONTRACTOR. Should damage be noted, ADWEA/End users/Engineer's may direct
CONTRACTOR to repeat the installation at CONTRACTORS cost.
If any boring operation fails, due to reasons not attributable to CONTRACTOR, or the boring
is rejected by ADWEA/End users/Engineer's the casing or carrier pipe shall not be withdrawn.
It shall be filled with concrete and plugged at either end. CONTRACTOR shall, in such case,
re-bore at an alternate alignment as approved by ADWEA/End users/Engineer's.
Boring machines used for installation of pipe shall be of the type approved by ADWEA/End
users/Engineer's.
All road crossings shall be provided with concrete safety barriers during construction.
3.11.4 Crossing of Buried Services
If any pipeline work under construction is to cross any existing buried facilities such as
pipelines, cables, and conduits, then this construction activity shall be approved in writing by
the authorities and is subject to ADWEA/End users/Engineer's approval. Type of crossing
shall be such that both the minimum clearance and the minimum depth of cover as required
by the drawings and specifications is guaranteed. The minimum clearance required between
pipeline and the existing facility shall be 300 mm in all direction. The pipeline shall cross
under the existing services unless permitted otherwise by the authority having the jurisdiction.
CONTRACTOR shall safeguard any buried services in the ROW that are to be crossed and
protection slab to be provided. The required protecting precaution shall be executed as
required and approved by the owners of the buried services and by ADWEA/End
users/Engineer's.
For buried services to be crossed by boring, the relevant provisions of this Section 3.11 shall
apply.
The minimum depth of cover to be provided at each road crossing is indicated in the
drawings. Before commencement of construction, CONTRACTOR shall obtain approval from
authorities having jurisdiction as to the requirement of cover to top of pipe for each crossing.
In case authorities having jurisdiction require deeper cover, CONTRACTOR shall install the
pipe at greater depth to fully comply with the requirements of authorities at no extra cost or
time to ADWEA/End users/Engineer's.
Client ADWEA

3.12 Final Clean-Up of the Construction Right-of-Way
3.12.1 Restoration of ROW
After completion of backfilling operations, the construction ROW and any other area affected
or used in connection with the pipeline construction shall be restored to its original contour
and condition to the approval of ADWEA/End users/Engineer's and to the satisfaction of the
Authority having jurisdiction.
Any surplus excavated materials, defective materials for the construction of the pipelines and
all trash, refuse and unusable spoil materials shall be collected and disposed of by
CONTRACTOR to an approved site.
Any loose rock scattered over the ROW or adjacent property shall be collected and disposed
of by CONTRACTOR to an approved site.
The construction ROW shall be graded smooth and surface soil shall be carefully replaced to
the approval of ADWEA/End users/Engineer's.
Any topsoil removed shall be reinstated in its original location with utmost care and the land
restored to its original condition.
Terraces, drainages or gutters, whether earth or masonry, destroyed by the construction

operations shall be reinstated to their original conditions.
All fences cut or damaged shall be reinstated by installing, if necessary, new sections of
fencing equal to or better than the sections cut or damaged. Temporary gates shall be
removed and replaced by new fence sections to the satisfaction of ADWEA/End
users/Engineer's and owner.
3.12.2 Progress of Intermediate and Final Clean-Up
Final clean up must not be left incomplete more than one kilometre behind completion of
backfilling except with the approval of ADWEA/End users/Engineer's. ADWEA/End
users/Engineer's will also have the right to suspend, without any compensation, the
CONTRACTOR's operations except for backfilling and clean up, whenever the final clean up
is left incomplete for more than the limits given above.
3.12.3 Pipeline Markers
CONTRACTOR shall provide suitable pipeline markers in compliance with the applicable
Typical Drawings, subject to ADWEA/End users/Engineer's approval, along the pipeline route.
They shall also be installed at each side of all road and major track crossings, foreign
pipelines and other utilities crossings, at changes in horizontal directions, and at all other
significant locations.
Client ADWEA

3.13 Encroachments and Working Near Other Utilities
In locations where pipeline has to be laid in any location under jurisdiction of

Government/Public Bodies, the CONTRACTOR shall perform such work in accordance with
requirements of the proper authorities. When it becomes necessary that CONTRACTOR has
to resort to hand digging, well-pointing or water removal by other means, erection of sheet
piling or any other special construction method in these areas, no extra compensation shall
be paid. CONTRACTOR shall contact the authorities concerned and ascertain their
requirements.
In locations where pipeline has to be laid more or less parallel to an existing pipeline, cable
and/or other utilities in the ROW, CONTRACTOR shall perform the work to the satisfaction of
the Owner/Authority of the existing pipeline/cable/utility. In such locations, the CONTRACTOR
shall perform work in such a way that even under the worst weather and flooding conditions,
the existing pipelines/utilities shall remain stable and shall neither become undermined, nor
have the tendency to slide towards the trench. All works carried out in the vicinity of existing
pipelines and associated installations shall comply with safety precautions as set out this
Specification, and ADWEA/End users/Engineer's Standards.
In locations where existing buried facilities such as pipelines, conduit cables or other
underground structures are to be crossed, prior to ditching, the location of these underground
facilities shall be confirmed by CONTRACTOR using pipe locators, cable locators, etc.
CONTRACTOR shall expose all buried facilities with hand tools before allowing mechanical
equipment to operate within ten (10) meters. In no instance shall mechanical equipment be
permitted to operate within 2 m of any existing buried service. These operations shall only be
performed after obtaining ADWEA/End users/Engineer's approval and work permits.
CONTRACTOR shall be liable for any damage occurring to, or resulting from, damage to
other pipelines and underground structures/utilities.
3.14 Detectable Warning Tapes
The CONTRACTOR shall furnish and place an approved type of detectable warning tapes
during backfilling work over all waterlines and ducts constructed in the PROJECT. The tape
shall be traceable by metal detector. Warning tapes shall be installed over any existing
waterline uncovered by the CONTRACTOR, over new utilities constructed by the
CONTRACTOR and over any waterlines included in the WORKS. Warning tapes shall be
placed in compacted backfill material, approximately 300mm below finished grade level, on
top of the concrete protection slabs or as directed by the ADWEA/End users/Engineer's.
The tape shall be 250 mm wide, blue coloured, plastic and aluminium coated with the
detection strip sealed at the edge. The tape shall have the warning "CAUTION – WATER
MAIN BELOW" in Arabic and English printed on it.
The warning tape for HDPE pipelines shall not be separately measured or paid for but shall
be considered as a subsidiary obligation under the items included in the Bill of Quantities.
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4. TESTING AND (PRE)COMMISSIONING
4.1 Test Procedure
4.1.1 General
Upon completion of the line or a substantial part thereof, sections of the line shall be cleaned
and hydrostatically tested to prove integrity of the pipe section and to detect any leakage prior
to commissioning. Testing shall be performed in accordance with the applicable codes and
standards, as listed in section 2.0. CONTRACTOR shall supply all necessary fittings,
equipment, facilities, etc. including test ends.
4.1.2 Method Statement
CONTRACTOR shall prepare detailed Method Statements (MS) for the pressure test, subject
to ADWEA/End users/Engineer's approval. These MS shall be based, but not limited to the
requirements as set forward in the applicable codes and standards and in this Specification.
4.1.3 Test Pressures
Test Pressure shall be 1.5 times the maximum allowable operating pressure (MAOP) for the
lowest element of the pipeline section under test for a maximum of 3 hours.
Under no circumstances shall the total time under test exceed eight (8) hours at 1½ times the
MAOP. If the test is not complete within this time limit (due to leakage, equipment failure,
etc.), the test section shall be permitted to "relax" for eight (8) hours prior to the next test
sequence.
4.2 Disinfection and Flushing of Water Pipeline
4.2.1 General
All water lines shall be disinfected by CONTRACTOR to the satisfaction of the ADWEA/End
users/Engineer's.
4.2.2 Method Statement
CONTRACTOR shall prepare a detailed MS for disinfection. This MS shall describe in detail
how the CONTRACTOR proposes to perform the various disinfection activities to ensure
compliance with the requirements as set forward in this Specification and applicable Codes
and Standards, as well as with all requirements as set forward by the relevant Authorities.
4.2.3 Disinfection and Flushing
Before the pipeline is placed in service, and before issue of the Provisional Acceptance
Certificate by ADWEA/End users/Engineer's, all pipelines shall be disinfected and flushed as
per AWWA C651 or as directed by ADWEA/End users/Engineer's
The pipelines shall normally be disinfected at the same time as the hydrostatic tests
performed or as directed by the ADWEA/End users/Engineer's.
Client ADWEA

One (1) week before the CONTRACTOR intends to undertake disinfecting/flushing of all or
part of the pipelines, the CONTRACTOR shall submit a detailed proposal for the work
showing the quantity of water required. This quantity of water may be obtained by the
CONTRACTOR from the nearest available ADWEA/End users/Engineer's source.
The chlorine dose shall be obtained from a chloral solution or other suitable solution to be
approved by the ADWEA/End users/Engineer's. Samples taken from the pipeline during
disinfection at locations directed by the ADWEA/End users/Engineer's shall be checked by a
suitable comparator in order to ensure that the sterilising liquid is present throughout the
system and at sufficient concentration.
At the end of the 24 hour period at operating pressure the chlorine concentration shall be
checked. If there is less than 1 mg/l of free available chlorine in the water, more chloral
solution shall be introduced and left for a further 24 hour period after which the free available
chlorine concentration shall be checked again. This procedure shall be repeated as
necessary until the free available chlorine taken after 24 hour s exceeds 1 mg/l for all samples
taken from the area of pipeline under test. The hydrostatic test shall not be commenced until
this requirement is satisfied.
Should the hydrostatic test fail and repair work involve emptying the pipeline then the
disinfection and subsequent testing procedures shall be repeated in full.
After all hydrostatic testing has been completed and section of pipeline is ready for handing
over in all other respects including the installation of connections where appropriate, the new
pipeline shall be flushed out by potable water from the existing mains to which the new
pipeline or network is or will be connected. Flushing entry and exit points shall be designed to
allow a minimum of 1.0m/s water velocity in the main pipeline to remove any sand or other
debris. The quantity of flushing water shall be calculated as the equivalent to 3 times the
volume of the pipeline to be flushed unless directed otherwise.
It shall be a condition that the water in the existing network at the point of extraction shall
register a minimum of 0.4 mg/l of free available chlorine when tested with a site comparator
prior to any approval being given to commence flushing. If a reading of less than this is
obtained the ENGINEER shall be informed and the CONTRACTOR instructed accordingly.
Once flushed, the water in the new pipelines shall be allowed to stand for a further 24 hours.
Samples shall then be taken from locations directed by the ADWEA/End users/Engineer's
and immediately submitted for chemical and bacteriological testing at the approved
laboratories. Chemical and bacteriological tests shall normally be undertaken at the End
users Laboratory and a charge may be made for testing. All charges for water sample testing
shall be paid by the CONTRACTOR.
4.2.4 Acceptance Criteria for Disinfection
The pipeline shall not be considered acceptable until faecal coliforms are undetectable in a
100 ml sample, the bacterial count is within approved limits, the recorded total chlorine
content is a minimum of 0.2 mg/l and the pH is within acceptable limits.
Client ADWEA

If the tests show that a satisfactory drinking water standard has not been achieved, the
CONTRACTOR shall repeat the disinfection procedure, tests and flushing, all at his own
expense, until these requirements are met.
The CONTRACTOR is responsible for making himself fully aware of the statutory
requirements for achieving acceptance of bacteriological and chemical standards of the water
in the pipelines under construction.
Flushing water shall be discharged via temporary discharge lines to the surrounding open
desert area or into the existing storm water system or, if feasible, into road tankers.
Discharging of flushing water into the existing storm water system shall be subject to approval
of the relevant Authorities.
Any temporary connections required for flushing shall be at the CONTRACTOR's cost. All
other materials, equipment and labour required for the disinfection, flushing operation and
discharge of water shall also be furnished by the CONTRACTOR and included in his
construction rates.
4.2.5 Connection to Existing Water Pipelines and Commissioning
With respect to the connection of newly completed pipelines into the existing distribution or
transmission system, and when successful pressure, chemical and bacteriological test results
for the same are available, the CONTRACTOR may request for connection into the existing
system in advance of preparing the new pipeline or network for handing over to ADWEA/End
users/Engineer's.
At least two weeks should be allowed for the application to be processed. The
CONTRACTOR shall follow strictly the timings and periods of shutdown of the existing system
as allowed by ADWEA/End users/Engineer's. A special permit shall also be fully completed
and authorised if a pipeline is to be shutdown for any connection, the shutdown application
forms for connection of newly laid section should be supported with the Site Hydrostatic Test
Certificate and Chemical and Bacteriological Test Certificate.
The CONTRACTOR shall prepare all labour, plant and equipment well in advance of the
proposed shutdown date and shall make advance preparations at the site of the connection
so as to minimise the amount of work required during the limited period of shutdown allowed.
No cutting of existing pipework shall be allowed until a representative of ADWEA/End
users/Engineer's Operation and Maintenance section has given his authority for the work to
commence after the necessary valves are closed. The ENGINEER shall also be present prior
to works being allowed to commence.
After the successful completion of the connection works and if agreed by ADWEA/End
users/ENGINEER, ADWEA/End users/Engineer's operation and maintenance section shall
again be called to re-pressurise the network. If a valve is installed at the subject connection it
shall be maintained in a closed position and shall only be opened for specific flushing
requirements at the instruction of ADWEA/End users/Engineer's representative.
Client ADWEA

Commissioning shall only be considered for approval by ADWEA/End users/ENGINEER
when the pipeline or network is complete in all respects and chemical and bacteriological
tests have been successfully concluded.
Handing over to ADWEA/End users/ENGINEER shall only be considered with respect to the
appropriate Clauses for Provisional Acceptance of the WORKS.
4.3 Pipeline Commissioning
CONTRACTOR shall commission the pipelines after pressure testing, disinfection, flushing
and after acceptance by ADWEA/End users/ENGINEER using procedures and plan approved
by ADWEA/End users/ENGINEER. CONTRACTOR shall prepare detailed Method
Statements (MS) with Work Procedure for the commissioning activities pipeline, subject to
ADWEA/End users/Engineer's approval. This MS shall be based on, but not be limited to the
requirements as set forward in the applicable codes and standards and in this Specification.
Once a procedure has been approved, any change in procedure shall be subject to written
approval from ADWEA/End users/Engineer's.
5. QUALITY ASSURANCE/Q UALITY CONTROL
A copy of the CONTRACTOR's QA/QC program shall be submitted to ADWEA/END

users/ENGINEER with its quotation for review and concurrence prior to award. If
CONTRACTOR's is ISO 9001:2000 certified, then only a copy of the ISO certificate is
required. In addition, if CONTRACTOR's facility is ISO certified, QA audit requirements will be
waived, unless 's trend analysis program indicates areas of concern.
The CONTRACTOR shall identify in documents to its manufacturers, suppliers, vendors and
subcontractors all applicable QA/QC requirements imposed by ADWEA/End
users/Engineer's, and shall ensure compliance. On request, CONTRACTOR shall provide
objective evidence of its QA/QC surveillance for all levels of its activity.
6. DOCUMENTATION
6.1 Records
6.1.1 General
CONTRACTOR shall submit daily, weekly, monthly and after completion to various records
and reports, for documentation purposes during and immediately after the construction. This
shall as a minimum include, but not be limited to the following:
6.1.2 Daily
• Separate progress reports of all crews
• Daily jointing results and repairs (& NDT results as per contract jointing spec)
Client ADWEA

• Actual weather conditions
• Application for variations, if any
• Next days working programme
• Accidents
• Damages
• Activities required from ADWEA/End users/Engineer's at short notice
• Material Receipts
• Urgently required materials
6.1.3 Weekly
• Up to date list of confirmed Site Instructions issued by
• Materials 'taken over'
• Material defects and repairs
• Outstanding activities of ADWEA/End users/Engineer's
• List of installed markers, chainage
• Required approvals from
• Progress planned
• Report of manning of all crews, equipment and plant
• Report of equipment and plant
• Report of accidents
• Report of damages
• Report of Acquired Releases, Permits
• Required materials for next week, etc.
Client ADWEA

6.1.4 Monthly
Progress report for payment, safety report, report of accidents, security report, health and
environment report, material balance, approved variations.
Further, C ONTRACTOR shall provide (for approval if required) ADWEA/End users/Engineer's

with documents such as but not limited to:
• Schedule for construction work
• Bio-data of key personnel (including foremen)
• (Revised) list of addresses of personnel in particular of medical staff, safety and security
officers
• Certificates of the welders
• (Revised) list of approved paint applicator
• (Revised) list of approved Subcontractors
• Time schedule
• Acquired permits and/or approvals from any Authorities, endowments
• Minutes of meetings with ADWEA/End users/Engineer's with comments, if any
• Material certificates, material receipts, etc.
• Guarantees from Vendors and Subcontract ors
• Calculations, temporary works, buoyancy, blasting, etc.
• Drawings issued by CON TRACTOR
• Vendor drawings
• All 'as built' drawings
• Procedures such as surveying, staking, fencing, etc., jointing procedures, jointer

qualification, installation of crossing, hydrostatic testing, blasting
• Pipe book and jointing records
• Material records and accounting book
• Test Reports
Client ADWEA

• Material tests (coating, jointing, painting, etc.)
• Water samples
• Cleaning, report before pressure testing
• Hydrostatic and Disinfection test
• Calibration test
• Equipment certificates (dead weight tester, instruments, vessels, equipment, etc.)
• Installation, operation, and maintenance manual s on all equipment
• Assembly drawings with keyed parts list on all equipment
• Two-year recommended spare parts list on all equipment
• Major water crossings
• Releases
6.2 As-Built Drawings and Pipe Book
6.2.1 General
CONTRACTOR shall prepare and submit 'as built ' drawings 6 month after issuing PAC at the
latest of all ADWEA/End users/Engineer's issued drawings and of all CONTRACTOR work
drawings including vendor drawings, such as, but not limited to (as applicable) :
• Route maps
• Changes of wall thickness, materials
• Location and details of valves, chambers, etc.
• Location and details of buried services
• Location and details of road, water crossings, etc.
• Location land details of casing pipes, vents, etc.
• Location and type of weighting, anchoring
• Location and type of markers
• Location of further fittings
Client ADWEA

• Location of ROW and of pipeline with respect to ROW
• Type of soil
• Type of rock
• Type of ripping
• Sand padding
• Type of road pavement
• Details of bank or plantation protection, etc.
The documents shall be provided as hard copy (number to be agreed during contract award)
and as soft copy. The drawings shall be prepared fulfilling the ADWEA enterprise GIS system
requirements and using the comptable AutoCad version to ADWEA.
6.2.2 Nameplates of Equipment
All permanent equipment installed by CONTRACTOR shall be provided with nameplates by

CONTRACTOR. All texts shall be submitted to ADWEA/End users/Engineer's for approval
before plates may be manufactured.
6.2.3 Pipe Book
Every page of the pipe book shall mention :
• Data relevant to the project and section thereof
• Length brought forward (for pipes and other materials)
• Length to bri ng forward (for pipes and other materials)
Alignment sheet number and at least the location thereon of two joints on every page of the
pipe book.
• Diameter of pipeline
• Length of each pipe
• Wall thickness
• Pipe Identification
• Date of stringing
Client ADWEA

• Date of jointing
• Direction of working
• Joint number
• Jointer number
• Type of jointing
• Limits of valve stations, water crossings, etc.
• Test pressure, date and test (hydrostatic)
• Length to bri ng forward (pipes and other materials)
• Length brought forward (pipes and other materi als)
In order to achieve this CONTRACTOR shall identify all pipe elements. Sample format of pipe
book shall be submitted ADWEA/End users/Engineer's approval. Final Pipe Book shall be
submitted to ADWEA/End users/Engineer's in the form of 1 hard copy (original) and 1 soft
copy on electronic format.
Client ADWEA

Specification For Construction, Testing & Commissioning of High Density Polyethylene (Hdpe) Pipe System

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Specification For Construction, Testing & Commissioning of High Density Polyethylene (Hdpe) Pipe System

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SPECIFICATION FOR CONSTRUCTION,

TESTING & COMMISSIONING OF HIGH

DENSITY POLYETHYLENE (HDPE) PIPE

project phase: project: document: W-P-SS-017 rev: 0 sheet: 1 of: 35

1. SCOPE OF SPECIFICATIONS ............................................................. 3

2. APPLICABLE STANDARDS AND CODES .......................................... 3

3. TECHNICAL REQUIREMENTS ............................................................ 3

4. TESTING AND (PRE)COMMISSIONING ............................................ 27

5. QUALITY ASSURANCE/Q UALITY CONTROL .................................. 30

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 2 of: 35

2. APPLICABLE STANDARDS AND CODES

Polyethylene (PE) Pipes for Water Supply – Specifications ISO 4427

Plastic Piping Systems for Water Supply Polyethylene (PE) BS EN 12201

Pipelines on land. BS 8010 : Part 1

Pipelines on land design, construction and installation. BS 8010 : Part 2

Disinfecting water mains. AWWA C651

CONTRACTOR shall prepare detailed Method Statements (MS), i.e. Construction

CONTRACTOR shall be deemed to have obtained all necessary information as above

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 3 of: 35

3.2 Pre-Construction Survey

The final pipeline alignment shall be subject to approval of ADWEA/End users/ENGINEER.

3.3 Right-of-Way (ROW)

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 4 of: 35

It shall be CONTRACTOR's responsibility to acquaint himself with all relevant requirements

For construction methods of crossings reference is made to section 3.11.

3.5 Clearing, Grading and Backfilling of ROW

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 5 of: 35

3.5.2 Fences and Barriers

On completion of construction the CONTRACTOR shall reinstate any damaged or relocated

Fencing and barriers shall be continuously maintained.

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 6 of: 35

3.5.4 Grading of ROW

3.5.5 Restricted ROW

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 7 of: 35

3.5.6 ROW Dama ges

3.5.7 Provisions of Detours

3.5.8 ROW in Rough and Rocky Terrain

3.5.9 ROW in Sand Dune and Sandy Areas

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 8 of: 35

3.5.11 Gatch Material for ROW

3.5.12 Minor Route Deviations

3.6 Handling, Hauling, Stringing and Storage

3.6.1 Pipe Material

3.6.1.1 Receipt of Pipe Material

Transportation of pipe to the construction site is the CONTRACTORS' responsibility.

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 9 of: 35

3.6.1.2 Handling of Pipe

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 10 of: 35

3.6.1.4 Care of Pipe

3.6.1.5 Hauling and Stringing of Pipe

3.6.2 Care of Other Materials and Properties

Materials supplied by the CONTRACTOR or free issued by ADWEA shall be stored in a

In case of any delays/interruptions in handing over of ADWEA supplied materials,

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 11 of: 35

Flammable materials shall be stored in special safe storage locations.

3.7.2 Normal Cover and Trench Dimensions

Project phase: project: document: W-P-SS-017 rev: 0 sheet: 12 of: 35

Normal Terrain and Sand Dunes 1.0 m (min)

Sabkha Area (On Prepared ROW ) 1.5 m (min.)

Track Crossings 2.0 m (min.)

City/Town/Inhabited Area 1.0 m (min.)

Metalled, Paved and Rig Road Crossings 2.0 m (min.)