Construction QA/QC

FRP Piping

Rev. No. Rev. Date Description of Revision Revised by Approval

00 21/April/2016 New KIA

PROPRIETARY & CONFIDENTIAL

This document and the information contained herein is E2C proprietary know-how. This document or any part
therefore should not be reproduced stored in a retrieval system or transmitted by any means, electronic or
otherwise, or divulged without permission of E2C.

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TABLE OF CONTENTS

1. Scope ............................................................................................................................. 3
2. Applicable Codes & Standards...................................................................................... 3
2.1 Codes & Standards .................................................................................................... 3
3. Witness Inspection Items ............................................................................................... 3
4. Test and Inspection Agenda .......................................................................................... 3
4.1 Inspection before Installation .................................................................................... 3
4.2 Installation of pipe ..................................................................................................... 3
4.3 Field Hydrotesting ..................................................................................................... 6
5. Documents to be Issued ................................................................................................. 8

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1. Scope
1.1 This specification covers the requirements & procedure for test & inspections of
installation of underground FRP piping at t h e c l i e n t construction site.

1.2 This specification shall be applied to the inspection items method and criteria for
Installation of FRP Piping work to be performed by the Construction Contractor.

1.3 Criteria established in this specification will be a minimum requirement. If there is any
conflict between manufacturer's standards and this specification, Construction Management
Contractor shall decide the prevailing specification after consultation with owner.

2. Applicable Codes & Standards

2.1 Codes & Standards
AWWA C950 Fiberglass Pressure Pipe
ASTM D3839 Underground Installation of Flexible Reinforced Thermosetting Resin Pipe
and Reinforced Plastic Mortar Pipe.
3. Witness Inspection Items
3.1 All installation construction work shall be subject to test & inspection under witness by
CMC and/or Owner's (Client) representative at any reasonable time and place before, during
and after construction.

3.2 Witness test and inspection items shall be in accordance with Table I.

4. Test and Inspection Agenda

4.1 Inspection before Installation
4.1.1 Prior to commencing the installation work, any damage, such as exterior scrape mark,
impact mark, bulges, laminations and/or abrupt curvature of the pipes, couplings and flanges
shall be inspected visually.

4.1.2 Internal inspection shall also be performed to check for damage of inside surfaces, such
as scrapes or impact marks, and to verify drainage of water and removal of foreign materials.

Pipe of doubtful condition or quality shall be immediately segregated from the construction
work, and shall not be used. Construction Contractor shall report segregated pipe to CMC for
evaluation, in conjunction with owner and manufacturer.

4.1.3 Construction contractor shall check the inspection report of the trench, bedding, location
or elevation of the pipe line to be installed.

4.2 Installation of pipe

4.2.1 Precaution during unloading, storing, transporting and handling pipe.

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4.2.1.1 Stacks of pipe shall be unloaded separately (one at a time), not as a unit. When
handling single pipes, at least two (2) pliable straps placed about four (4) meters apart, with
the lifting equalizer, if applicable, shall be used to lift.

Rubber ring gasket and lubricant shall be carefully stored in the shade in their original
packaging to prevent damage.

4.2.1.2 Maximum stack height shall be 3 meters, but not more than three (3) pipes steps for
pipes larger than 800 mm diameter. Stacking of pipes larger than 1400mm diameter is not
recommended. Stacks must be secured to prevent movement and possible damage.

4.2.1.3 The pipes shall be loaded on the truck by using original shipping dunnage, or flat
timbers spaced on a maximum of 4 meter centers with maximum over-hang of 2 meters. The
pipes shall be chocked to maintain stability and separation, to ensure no pipes contact other
pipes during transporting.

4.2.1.4 If at any time during handling or installation of pipes, any damage, such as a gouge,
crack or fracture occurs, the pipes shall be repaired or replaced as directed by CMC and
owner. CMC shall be immediately advised of such damage.

4.2.2 Joining pipe

4.2.2.1 During joining work of the pipes by using double bell couplings, Construction
Contractor shall inspect the following items:

a. Verify that all dirt or oil has been removed from coupling grooves, rubber ring and/or
gasket ring. All foreign material shall be removed by cleaning with rags and removal shall be
verified by visual examination.
b. Verify that a thin film lubricant (vegetable oil based soap) to the rubber gasket and the
pipe from the end to black positioning stripe has been applied with clean rags.
c. Verify that the double bell coupling and pipe has been aligned.
4.2.2.2 During joining work of the pipes by using flanged joints, Construction Contractor shall
inspect the following items.

a. Verify that the flange face and 'O' ring groove are clean. (no dirt or oil).
b. Verify that the 'O' ring gasket is clean and undamaged. (A thin film of lubricant shall
be applied with a clean rag to lubricate the gasket).
c. Verify that correct flange alignment has been performed.
d. Verify that all hardware (bolts, washers, and nuts) are clean and lubricated.
e. Verify that all bolts have been tightened to 3.5 Kg.m (25 ft. lb) torque, using a torque
wrench. Maximum flange bolt tightening torque shall be 7 Kg.m (50 ft.lb).

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4.2.3 Backfilling of piping

4.2.3.1 Pipe bedding material shall be compacted to a minimum 90% of max. dry density
(70% of maximum relative density for crushed rock, crushed stone and gravels), unless
otherwise specified on construction drawings.

4.2.3.2 The finished bed shall be plane, 150 mm deep minimum below pipes and shall provide
continuous support for the pipe. Construction contractor shall inspect over-excavation of the
bed at each coupling (joint) location to insure that pipe will have continuous support.

4.2.3.3 The field compaction test for bedding material shall be done in accordance with Client
requirement.

4.2.3.4 The backfill material for pipe zone shall be the same as the bedding material. The
backfill material shall not be frozen or contaminated with debris or other foreign matter that
could damage the pipe or cause loss of side support.

4.2.3.5 During backfilling, the construction contractor shall make certain that the granular
material flows completely under the pipe to provide full support.

4.2.4 Method and Sequence of Pipe Back Filling

Checking the installed pipe. The diametrical deflection for installed pipes shall be inspected as
follows.

4.2.4.1 Initial Vertical Ovalization Check. Initial deflection of each pipe shall be inspected
after installation. The initial deflection shall not exceed 3% of the nominal diameter.

If initial deflection exceeds 3%, pipes must be changed of installed direction or replaced so
that the initial defection is less than 3%.

4.2.4.2 Interim Pipe Deflection Check. After backfilling and compaction of the pipe zone,
check of interim deflection of each pipes shall be performed to check compaction density. The
expected amount of ovalization at this point shall be 1.0 to 2.0% of diameter for highly
compacted sand. Deflection shall not exceed 3% of the nominal diameter.

4.2.4.3 Final Pipe Deflection Check. Checking of final deflection of the pipes shall be done for
each pipe immediately after completion of backfilling.

Procedure for checking the final diametrical deflection for installed pipes shall be as follows:
a. Complete backfilling to grade.
b. Complete removal of temporary sheeting (if used)
c. Turn off the dewatering system (if used)
d. Measure and Record the pipe’s vertical diameter
e. Calculate vertical deflection.
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% Deflection = Design I.D – Installed Vertical I.D x 100%

100
f. Maximum installed diametrical deflection shall not exceed 3% of the normal diameter.
g. The final deflection shall be measured at intervals of each pipe or 10 Meters,
whichever is greater, using inside bar gauge.
4.2.4.4 Pipes installed with interim or final diametrical deflections exceeding 3% must be
corrected to insure the long-term performance of the pipe in accordance with the following
procedure.

a. 3% to 8% Deflection
(i) Excavate to near the pipe invert/haunch depth. Excavation just above and at the sides
of the pipe should be done utilizing hand tools to avoid impacting the pipe with heavy
equipment.
(ii) Inspect the pipe for damage. Damaged pipe should be repaired or replaced.
(iii) Recompact the haunch backfill insuring it is not contaminated with the native soil.
(iv) Rebackfill the pipe zone in lifts with the appropriate material compacting each layer as
required by the cover depth to limit the pipe deflection.
(v) Refill to grade and check the pipe deflections to verify they have not exceeded 3%.
b. > 8% Deflection
(i) Pipes over 8% deflection should be replaced completely.
4.2.4.5 The installed piping shall be inspected for location, elevation and the condition of
contract encasements, such as thrust blocks or thrust/stress blocks, anchor, and support etc. in
accordance with construction drawings, and "Inspection Procedure of Concrete Work, Doc.

Acceptance tolerance shall be as follows:

a. Vertical (Elevation). Deviation from a given level (grade elevation) shall not exceed
+10mm. Deviation from specified gradient in gravity pipe lines shall not exceed 5% of the
specified gradient.

b. Horizontal (Location). Deviation from horizontal alignment shall not exceed 1% of

pipe nominal diameter.

c. Thrust blocks and/or thrust/stress blocks must limit the displacement of the fitting to
0.5% of the diameter or 6mm, whichever is less.

4.3 Field Hydrotesting

4.3.1 The method of field hydrotesting is the following two (2) cases.
4.3.1.1Case – 1. Joint testing with internal test jig, before backfilling, followed by full-line test
after backfilling.
a. Individual joint hydrotesting of line larger than 750mm shall be done
beforebackfilling.
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b. After joint testing and backfilling are complete, the entire lines or line sections must be
retested as a whole.
4.3.1.2 Case – 2. Full line testing without individual joint test.

a. Lines or line sections, such as smaller than 750mm. must be tested as a whole prior to
backfilling.
b. Lines or line sections shall be restrained sufficiently to prevent movement prior to
hydrotesting.
4.3.2 In case of performed full line testing before and after backfilling, Construction
Contractor shall arrange the hydrotesting of the entire lines or line sections as follows:

4.3.2.1 Filling the line with water. Open valves and vents, so that all air is expelled from the
line during filling and avoid pressure surges.

4.3.2.2 Pressurize the line slowly. Considerable potential energy is stored in a pipe line under
pressure and this power should be considered during pressurizing operation.

4.3.2.3 Ensure the gauge location will read the highest line pressure, otherwise adjust
accordingly. Locations lower in the line will have higher pressures due to additional head in
the pipe. All gauges must be calibrated.

4.3.2.4 Ensure the maximum test pressure does not exceed the specified value. Test pressure
or test fluid shall be in accordance with construction drawings, or Test flow/Line Table List.

4.3.2.5 The test pressure shall be maintained for a period of min. 30 minutes and inspected
visually for no weeping or leakage. The weeping or leakage from joints or piping shall be
rejected.

4.3.2.6 In case of hydrotesting after backfilling, the lines or line sections shall be observed for
a period of min. 2 hours. During this time, the lines or line sections pressure shall not drop.

4.3.2.7 If, after a brief period for stabilization, the line does not hold constant pressure, ensure
that thermal effect (a temperature change) or entrapped air is not the cause. If the pipe is
determined to be leaking and the locations is not readily apparent, the following methods may
aid discovery of the problem source:

a. Check flange and valve areas

b. Check line tap locations
c. Use colored water
d. Use sound detection equipment
e. Test the line in smaller segments to isolate the leak
4.3.2.8 After the pressure test, the lines or line sections shall be emptied and inspected for
surface cracks or structural damages.

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5. Documents to be Issued
5.1 After final inspection, all test records and check sheet for test and inspection given in
Table-1 shall be issued in the form of QC dossier.

5.2 The QC Dossier shall be submitted in accordance with Client requirement.

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