Annex IV - Chapter 5-Pipeline Installation PDF

PIPELINE INSTALLATION
Table of Contents
CHAPTER 5 – PIPELINE INSTALLATION
TABLE OF CONTENTS
Page Nr.
CHAPTER 5 PIPELINE INSTALLATION 1
SECTION 5.1 - PIPE LAYING 1

5.1.1 General Requirements............................................................................................................... 1
5.1.2 Installation of Pipe and Fittings................................................................................................. 2
5.1.2.1 Installation of Ductile Iron (DI) Pipe and Fittings .................................................................... 2
5.1.2.2 Installation of Steel Pipe (SP) and Fittings ............................................................................. 5
5.1.2.3 Installation of PE Pipe and Fittings .......................................................................................... 6
5.1.2.4 Installation of Un-plasticized Polyvinyl Chloride (uPVC) Pipe and Fittings ...................... 11
5.1.2.5 Installation of Galvanized Steel (GS) Pipe and Fittings ...................................................... 13
5.1.2.6 Installation of Reinforced Concrete (RC) Pipe and Fittings................................................ 13
5.1.3 Exposed Piping ......................................................................................................................... 14
5.1.4 Canal or River Crossing and Culvert Crossings .................................................................. 15
5.1.5 PIPELINE MARKER TAPE .................................................................................................... 15
SECTION - 5.2 CONNECTIONS TO EXISTING MAINS........................................................... 16
5.2.1 General ...................................................................................................................................... 16
5.2.2 Execution ................................................................................................................................... 17
5.2.3 Testing........................................................................................................................................ 17
SECTION - 5.3 INSTALLATION OF VALVES & MARKER POSTS .......................................... 17
5.3.1 General ...................................................................................................................................... 17
5.3.2 Materials .................................................................................................................................... 18
5.3.3 Location of Installation ............................................................................................................. 18
5.3.4 Execution ................................................................................................................................... 18
5.3.5 Installation of Marker Posts ..................................................................................................... 19
SECTION 5.4 - TESTING & DISINFECTION ............................................................................ 19
5.4.1 General ...................................................................................................................................... 19
5.4.2 Colouring Tests for Welding.................................................................................................... 19
5.4.3 Field Hydrostatic Pressure Test ............................................................................................. 20
5.4.4 Field Leakage Test ................................................................................................................... 20
5.4.5 Disinfection ................................................................................................................................ 21
5.4.6 Connection of Pipes and Fittings ........................................................................................... 23
SECTION - 5.5 PIPE JACKING FOR RAILWAY CROSSING ................................................... 23
5.5.1 Scope of Work........................................................................................................................... 23
5.5.2 General Requirements............................................................................................................. 23
5.5.3 Driving Pipe ............................................................................................................................... 24
5.5.4 Driving and Arrival Shaft .......................................................................................................... 24
5.5.5 Cutting Edges............................................................................................................................ 24
5.5.6 In-Pit-Based Jacks ................................................................................................................... 24
5.5.7 Installation of Casing Pipe ....................................................................................................... 24
5.5.8 Submittal of Shop Drawings and Reports ............................................................................. 25
UNOPS – SDOC ToC - I

General Technical Specification
CHAPTER 5 PIPELINE INSTALLATION
SECTION 5.1 - PIPE LAYING
5.1.1 General Requirements
The Contractor shall provide all labour, materials, equipment and incidentals required to install, test, clean
and disinfect all new water pipelines.
All pipes shall be laid to lines and grades as shown on the Drawings and to comply with BS 8010 Section
2 “pipe lines on lands: Design, Construction and Installation”. The type of bedding and minimum clear
cover to the pipes shall be as shown on the Standard Drawing or else where in the Contract Document
but not limited to what is shown therein. Pipes, fittings and valves that are supplied either by the
Contractor or Employer (Transmission Mains only) shall be used in this work. Loading, transporting and
handling shall be done very carefully as described in conformance with the recommendations of the
manufacturer.
Pipe end covers and other transit protections provided by the pipe supplier shall be retained in place
except for taking over inspections until the pipes are finally inspected shortly before they are laid in
trench. All pipes, fittings and accessories shall be examined and no piece, which is found to be defective,
shall be installed. When pipes, fittings, etc. are strung adjacent to the pipe trench prior to laying they shall
be supported clear of the ground on suitable approved prop up to prevent damage to their external
coating. Excavation, bedding and backfilling shall be done as specified in Part I - Section 2.3 “Trench
Excavation” and in this section, all to the satisfaction of the Engineer.
The open ends of the installed pipes shall be plugged with a watertight cap or by other approved means
after the Contractor has finished the installation works on each working day until he is ready for
continuation of pipe laying subsequently. The Engineer reserves the right to order the Contractor to
remove any pipe length or lengths that has not been plugged as required for cleaning the inside of the
pipes before reuse. Material to be used for plugging shall be approved type that shall adequately protect
the pipe from damage, and prevent dirt, debris and water from entering the pipe. The Contractor shall
prevent trench water, mud, sand or sewage from entering the pipe during installation.
The type of joint required for each pipe material shall be in accordance with provision in this Specification.
All rubber joint rings and gaskets must be stored in a cool damp location in black polythene bags and
shall not be distributed to the trench side until just prior to its assembly thereof. Rubber gaskets shall be
well lubricated prior to fitting. Particular care shall be taken during joining the pipes and all pipefittings
shall be checked for defects and thoroughly cleaned before joining.
Any field cutting of the pipe shall be done only with the approval of the Engineer. The Contractor shall
submit to the Engineer for prior approval details of his cutting method along with types and sizes of pipes
to be cut. Any damage to the coating and/or lining shall be immediately repaired. Where cut pipe has
been installed without complying with the above requirements and prior approval of the Engineer and the
work is found not to conform to the specifications, the Engineer has the right to order the Contractor to
remove that pipe length for rectification. All expenses involved in this process shall be borne by the
Contractor.
Each pipe and fitting shall be laid true to alignment, curve and gradient in accordance with the drawing or
as directed by the Engineer. The minimum cover and the minimum gradient shall unless otherwise stated
UNOPS – SDOC C5-1

not be less than one metre and 1:400 respectively. The pipes shall be laid to even gradients and sight
rails shall be provided for this purpose at intervals not exceeding 50 metres and at changes of direction
and grade. Pipes and fittings suppose to be exposed at culvert or bridge crossings and in manholes or
chambers shall be painted in accordance with requirement of the Engineer.
The following applicable standards are referred to various pipe materials:
ISO 4482 Asbestos-Cement Coating – Guide for laying

AWWA C203 Coal-Tar Protective Coating and Lining for Steel Water Pipeline –
Enamel and Tape-Hot-Applied
AWWA C206 Field Welding of Steel Water Pipe Joints
AWWA C210 Coal-Tar Epoxy Coating System for the Interior and Exterior of Steel
Water Pipe
AWWA C600 Standard Specifications for the Installation of Gray and Ductile Cast-Iron
Water Mains and Appurtenances
AWWA C603 Standard Specification for the Installation of Asbestos-Cement Pressure
Pipe
AWWA Manual M11 Steel Pipe Design and Installation
5.1.2 Installation of Pipe and Fittings
5.1.2.1 Installation of Ductile Iron (DI) Pipe and Fittings
All pipes shall be carefully inspected for defects before installation. No pipe or a fitting that
shows defects excluded by the specification shall be used. Any injury to protective coating of the
pipe or fittings shall carefully be repaired before installation at no extra cost to the Employer.
The Contractor shall after excavating the trench and preparing the bed for laying the pipes,
furnish all necessary facilities for properly lowering and placing the section of the pipe in trench
without damage and shall properly install the pipe subsequently. The section of the pipe shall be
fitted together correctly and laid true to line and grade in accordance with the benchmark
established by the Contractor. The full length of the barrel of the pipe except the socket (bell) or
flange shall have a uniform bearing upon the bed of the trench. Suitable excavation shall be
made to receive the socket (bell) or flange, which shall not bear on the sub-grade.
The pipe shall be lowered into trench using cranes as far as possible and no pipe shall be rolled
into place for lowering into the trench except over suitable timber planking free from roughness
likely to damage any coatings. If the prepared bed is damaged for any reason, the pipe shall be
raised and the bed made good before pipe laying is continued. The open end of the pipeline
shall be securely closed with a tight fitting plug or cover whenever the work interrupted for any
reason. The interior of each pipe after being laid shall be thoroughly cleaned. Any pipe that is
not in true alignment both vertical and horizontal or experience any undue settlement after
laying shall be taken up and re-laid correctly by the Contractor at his own expenses when so
ordered by the Engineer.
Any underground water encountered in the pipe trench shall be pumped out regularly and the
water level be kept below the sockets when joining. In no case shall pipes and/or fittings be
jointed before being lowered into its final destination in the trench. Any damage occurs to the
UNOPS – SDOC C5-2

pipes through failure of the Contractor to comply with these conditions shall be made good at
the Contractor’s expenses.
The Contractor shall take necessary care to install the pipes with polyethylene sleeves or tape
wrap in locations where instructed, strictly in accordance with the specifications of the
manufacturer and using the recommended material, tools and equipment and methods that are
recommended. The sleeves or tap wrap fails to provide the protection to the pipe as intended
due to improper material, tools or methods used by the Contractor in the opinion of the
Engineer, then he shall replace the sleeves or tape wrap in the affected area as directed by the
Engineer at no extra cost to the Employer.
(i) Concrete Protection of Pipe
The pipe shall be encased in concrete in accordance with the details shown on the drawings or
instructed by the Engineer. Such concrete shall not be placed until the joints at each end of the
pipe have been completed. Each pipe to be encased shall be supported on at least two purpose
made pre-cast concrete blocks of same grade of encasement concrete which shall be left in
place and the full width and depth of concrete encasement shall be placed and carefully tamped
beneath the pipe followed at once by the addition of the encasing concrete.
(ii) Push-in Joints and Restrained (Self Anchored) Joints
Installation of pipes shall be in accordance with the recommendations of the pipe manufacturer.
Sockets and spigots shall be thoroughly cleaned prior to making the joint. Only lubricant
recommended by the manufacturer shall be used and it shall be non-toxic. The completed joint
shall have a uniform contract by the gasket between the outer surface of the spigot and the
rubber ring seat of the socket.
(iii) Flanged Joints
Joints shall be made up square with even pressure upon the gasket and shall be properly
watertight. Gaskets shall fit the inside dimension of the pipe accurately so that no surface
material projects out into the flow area. The completed joint shall be perfectly aligned. Flanged
joints shall be coated including all bolts and nuts with Denso paste and primer, Denso mastic,
Denso tape and PVC or polyethylene outer wrapping.
(iv) Slip-on Coupling, Collars and Flange Adapters
Coupling, collars and flange adapters, which are as specified shall be used where shown on the
drawings and as approved by the Engineer. Installation shall be accordance with the
manufacturer’s recommendations. Gasket seats and gaskets shall be thoroughly cleaned before
assembly. The completed joint shall have uniform contract by the gasket between the outer
surface of the spigot and the gasket seat at the socket. Coupling and flange adapters shall be
coated including all bolts and nuts with Denso paste and primer, Denso mastic, Denso tape and
PVC or polyethylene outer wrapping.
(v) Deflection of Pipeline
UNOPS – SDOC C5-3

Minor deviation of direction in pipeline both vertically and horizontally shall be achieved through
deflections at the joints. Such deflections shall not exceed the values given below or as
stipulated by the pipe manufacturer.
Nominal Diameter Maximum Allowable Deflection (degree)

(mm) Push-on Joint Mechanical Joint
80 to 200 5.0 5.0

250 to 350 4.0 4.0
400 to 600 3.0 2.5
700 to 900 2.5 2.0
1000 to 1200 2.0 1.5
1400 and above 2.0 1.2
Joints with deflection shall be installed in accordance with the manufacturer’s instruction.
(vi) Cutting of Pipes
Pipe shall be cut using power driven abrasive wheel cutting machine. Acetylene torch and chisel
methods will not be permitted in any circumstances. Cut spigot ends shall be beveled to the
same dimensions as the normal spigot ended pipe. The edges of the cutter shall be given two
coats of approved paint and the internal coating shall be repaired if damaged. The Contractor
shall ensure that the diameter at the point of cutting will match the pipe to which it is to be
jointed.
(vii) Welding
The Contractor without the approval of the Engineer shall not undertake site-welding work on
ductile iron pipe and fittings. Welding work shall be undertaken in accordance with the
manufacturer’s recommendations when approved by the Engineer.
(viii) Protection of Joints
All buried flange joints, and any un-coated mechanical coupling shall be protected by wrapping
with “Denso Paste”, “Densyl Mastic”, “Densyl Tape” and “PVC Outerwrap” manufactured by
Winn and Coales Limited, Denso House, Chapel Road, London, S.E.27 or similar approved
materials. The joints shall be thoroughly cleaned to remove all loose rust and extraneous matter
and thoroughly coated with “Denso Paste” over the whole of the joint. A liberal amount of paste
should be left around all bolt heads, narrow cavities, etc.
“Densyl Mastic” shall then be applied to cover all bolt heads and nuts to form a triangular fillet
against flanges and to fill all gaps and abrupt changes in contour to provide an even contour for
wrapping. “Densyl Tape” shall be applied circumferentially, care being taken to smooth and
eliminate any air pockets and to form the tape well into all angles and changes in contour. The
tape shall be applied with an overlap of at least 25 mm and extend at least 50 mm on either side
of the joint.
UNOPS – SDOC C5-4

Finally an outer wrapping of “PVC Outerwrap” shall be applied with minimum lap of 25 mm to
completely cover the “Densyl Tape”. Contractor may use any equivalent joint protection
materials exclusively with the approval of the Engineer.
5.1.2.2 Installation of Steel Pipe (SP) and Fittings
All pipes and fittings to be used in this work shall be in accordance with Section 4.3.2 “Pipe
Material”.
All pipes and fittings shall be handled and installed in accordance with the applicable section of
AWWA Manual M11 and the requirements described herein.
The exposed steel pipes and fittings shall be painted with two coats of synthetic red lead primer
and one coat of aluminum paint at crossings over canals and ditches. The underground steel
pipe shall be tied around with synthetic asbestos cloth. Steel sleeve pipe shall be painted with
two coats of coal-tar epoxy.
The ends of the pipe shall have wooden stiffeners installed inside of the pipe at quarter points
and at both ends of the pipe. This blocking shall remain inside the pipe until the pipe has been
ready for installation. When field cutting or mitering of the pipe is required, the acceptable
cutting machine leaving a smooth cut at right angles to the axis of the pipe or deflection angle
shall do the cutting. Cut ends of the pipe shall be beveled with a special tool made for this
purpose and the beveled end shall be exactly the same as the plain end of the pipe as
manufactured at the factory.
Steel pipe with plain ends shall be joined together with a flexible coupling as specified, or where
shown on the drawings. The Contractor shall make excavation of sufficient width and depth to
provide the suitable room for joining the pipes and fittings. The bedding at the joint shall be
installed and compacted after the joining has been completed. Where fittings such as bends,
tees and blanks are used, all fittings shall be joined with single butt-welded joints unless
otherwise shown on the drawings.
Any damage inflicted to the exterior coating and interior lining shall be repaired in accordance
with the manufacturer’s recommendations. In the opinion of the Engineer, the damage is not
properly repaired by the field method, the Engineer reserves the right to order the Contractor to
use the method of repairing that is the same as the manufacturer’s procedure. The expenses of
repairs shall be borne by the Contractor.
Welded joints shall be butt and weld and in full conformance with AWWA C206. Welders in
charge shall have the qualification stipulated in JIS Z3801 or equivalent. The Contractor shall
submit the qualification of the proposed welders for the steel pipe jointing for the approval of the
Engineer. The Engineer may request the Contractor to conduct special test welding session to
verify the capability of the welders. The Contractor shall, when requested by the Engineer make
the necessary arrangement for such testing for joint welding at his own cost.
Subsequent to satisfactory completion of all field welded joints and approved by the Engineer,
the joints shall be provided with the protective coating and lining as specified below.
(i) Coal Tar Enamel Coating (Underground Buried pipe)
UNOPS – SDOC C5-5

All field welded joints in the underground buried pipeline shall be field-coated with coal tar
enamel and bonded with double asbestos felt wrap in accordance with BS534 or Appendix A
Section A1.2 of AWWA203. The coating system shall be equivalent to the shop-applied coating
of the pipe section and shall be applied across and around the outside of the joints. The joints
protective coating shall overlap the main body of the shop coating on each side of the field joint
to form a continuous coating free from defects. The overlapping length shall be at least 200 mm
on each side of the joint.
(ii) Epoxy Painting (Above-ground Exposed Pipe)
All field-welded joints in the aboveground level exposed pipeline shall be field coated with at
least two (2) coats of epoxy resin paint. The first and second coats shall be of minimum coating
thickness not less than 40 and 30 microns, respectively. The Engineer from the samples
submitted by the Contractor shall determine the colour of epoxy paint. The method of field
painting shall conform to the paint manufacturer’s instruction and recommendations. Unless
otherwise permitted by the Engineer, shop coating and field-painting materials shall be from the
same manufacturer.
(iii) Cement Mortar Lining
All field-welded joints shall receive field applied protective cement mortar lining in accordance
with AWWA C602. The lining system shall be equivalent to the shop applied lining and shall be
applied across the inside of the joints.
Bolts and nuts for mechanical joints, flanged joints and blank flanges shall be given a coat of
bituminous paint after the jointing has been completed.
5.1.2.3 Installation of PE Pipe and Fittings
(i) General
All PE pipes and fittings shall be inspected carefully for any possible defects prior to installation
and any pipe shows defects shall not be used for the works. The PE pipes shall be jointed by
employing any one of the methods namely electro-fusion or butt-fusion. In general, pipes for this
project shall be jointed with butt fusion method of welding.
(ii) Transportation and Storage
Polyethylene is a resilient, lightweight and easy to handle material. Adequate care shall be
taken to prevent scuffing or gouging of the surface. The PE pipes shall be transported and
stored carefully in order to avoid external mechanical damage. Large quantities of straight pipe
tubes are transported in unit piles. Vehicles for transporting bulk loads shall be provided with a
clean flat bed free from nails or other projection that may cause damage to pipes. Extra care
shall be taken to prevent excessive bowing and tumbling of pipes as well as stacking near sharp
edges. Smaller diameter coiled pipes shall be placed either horizontally or vertically during
transportation provided that the highway regulations are not violated. Pipes shall not be allowed
to rest on the integral socket and the fittings shall not be loaded in a way that could distort the
ends. Precautions shall be taken when stacking pipes and fittings near heat sources including
UNOPS – SDOC C5-6

exhaust system to prevent damage. Contamination with materials such as grease, diesel oil,
lubricants, hydraulic oils, gasoline, solvents, other aggressive chemicals etc. shall be avoided.
Large quantities of straight pipe tubes are transported in unit piles. Loading and off-loading of
pipes shall preferably be performed with the aid of non metallic wide band slings or ropes and
load spreading beams of length not less than a quarter of that of the pipe or bundle pack shall
be employed for pipes of over 6m length. Hooks, metal chains or slings are usually not
permitted for this purpose but in any case shall not be allowed to have direct material contact
with the pipes. Any damage to pipes and pipe ends during lifting shall be avoided particularly for
those pipes with couplers. Forklift trucks may handle bundled packs of standard 6m length pipes
by properly placing the forks and lifting in order to take care of the flexible nature of the pipes.
Bundled packs of greater than 6m in length shall be managed either by a side loader with a
minimum of four supporting forks or by a crane using a spreader beam and suitable slings. The
flexible nature of the pipes permit certain degree of bending at the middle during lifting and thus
the lifting points shall always be well spread and evenly spaced.
Pipes and fittings shall be meticulously inspected at the time of delivery for any defects. Any
defective material identified during delivery shall be set aside and promptly notified to the supply
source either for repairs or replacement. Pipe with incise in excess of 10% of wall thickness
shall be clearly marked as damaged and discarded. The pipes shall be stacked on a sufficiently
firm and flat ground to support the weight of the pipes and movement of necessary lifting
equipment. Height of stacking shall be kept to a minimum but in any case not more than 3m or 3
bundle height which ever is less and adequate space allowed in the storage area for lifting
machinery to maneuver freely without causing accidental damage. Materials of different polymer
manufacture shall be clearly identified and kept separately. Polyethylene fittings shall be stored
under a roof cover preferably on racks with manufacturer’s wrapping on or kept intact with
cartoons until lifting is required for use.
The individual pipes, fittings or bundles shall not be dragged or dropped from the delivery
vehicles. Protective packaging such as buttons, shirk-wrap, pallets, strapping, etc. shall be
intact until individual items are required for use. Pipes and fittings shall be kept well away from
sharp objects such as flints. Special care shall be exercised when handling slippery prone pipes
in wet conditions. Pipe lengths stored individually shall be stacked in a pyramid like shape of not
more than one meter high with the bottom layer fully restrained by wedges. The bottom layer of
pipes shall be laid on timber battens placed at one-meter centre where possible. Pipe end caps
shall be left in place to prevent the ingress of dirt, vermin etc.
Black coloured PE pipes may be stored under the open air without any restriction up to a period
of 12 months and utilization after longer periods of storage shall be subject to material quality
tests. Blue polyethylene pipes shall preferably be stored under cover and protected from direct
sunlight beating until required for use. Pipes stored outside and exposed to direct sunlight shall
be covered with opaque protective sheeting material such as black polyethylene sheeting that
contained pigment to provide an excellent protection against degradation due to UV radiation.
Fittings that are to be joined by electro-fusion welding shall be stored under cover in dry
conditions preferably on racks or kept in their respective boxes intact with plastic packaging until
ready for use. Materials subject to butt-fusion and spigot end fittings may be stored outdoors
provided that they are sufficiently protected against damage and prolonged direct sunlight
beating.
(iii) Excavation
UNOPS – SDOC C5-7

The Contractor shall initially carry out a recognizance survey along the proposed pipeline route
with the assistance of the representatives from relevant authorities to identify the existing utility
service lines within the right of way. Some of the existing utility service lines identified in the
pipeline route have been indicated in the tender drawings but its accuracy cannot be assured
and the Contractor shall be fully responsible for the establishment of the true situation. The
Contractor immediately with the consent of the authority concerned shall rectify any damage
inflicted to the existing services without any additional cost to the contract.
The width and the depth of the trench shall be in compliance with the relevant drawings
provided by the Employer. The width of excavation normally governed by the diameter of the
pipe shall be kept to a minimum and limited to its outer thickness plus 250mm. The minimum
depth of cover shall be 900mm between the crown of the pipe and the finished ground
elevation. Excavators with narrow buckets are best suited to conventional trenching method in
most instances. The trench width may be further reduced in areas where several lengths of
pipes could be fused together by butt-welding to form continuous strings and hence the need for
trench jointing is virtually eliminated. A minimum of three-pipe length to be installed shall be
excavated prior to laying. In the event of installing more than one row of pipeline in the same
trench, adequate working space shall be allowed between the pipelines to facilitate construction
as well as subsequent operation and maintenance.
(iv) Installation of Pipes
All PE pipes and fittings shall be inspected carefully for any possible defects prior to installation
and any pipe shows defects shall not be used for the works. The installation of PE pipes is
relatively easier due to its lightness and flexibility coupled with durability and entirely secured
jointing methods. It is absolutely essential to ensure that the PE pipes are laid on a bed of
granular materials to provide even and continuous support along the whole length of pipe. A
minimum of 100 mm thick bed of granular material free from large stone from trench excavation,
gravel, and broken stone graded between 5mm to 10mm, coarse sand, sand and gravel mix are
all acceptable as bedding material. Polythene pipes may be laid directly on the trimmed bottom
of the trench in some instances where the soil is uniform, fine grained, relatively soft and free
from large stones and flints but subject to approval of the Engineer. The type of bedding
material and its thickness is usually specified in the tender drawings. Caution tapes (warning
tapes) shall be installed in the pipe trench 500 mm above the crest of the pipe for all diameters
of PE pipes.
Butt fusion method of welding shall generally be employed for the jointing of PE pipes under this
contract. Butt fusion method of welding shall only be used for jointing similar grades and SDR of
PE pipes.
(v) Backfilling
The high flexibility of polyethylene material permits certain degree of deformation under load
without any damage. However, it is important that the actual deformation is minimized as much
as possible by systematically placing the backfilling material in the trench. The quality of the fill
material up to a height of 100mm above the pipe crown shall be in compliance with WIS 4-08-
02. Initial backfilling including side fill shall be carried out carefully with sufficient compaction
but without employing any heavy compaction equipment up to a height of 250mm above the
crown of the pipe. Backfilling above this level shall proceed in layers of 250mm of maximum
thickness till the final ground elevation using heavy mechanical equipment. Temporary
UNOPS – SDOC C5-8

reinstatement of road surface belonging to relevant road authority on completion of pipe laying
shall be executed in compliance with their respective specifications or as otherwise instructed
by the Engineer.
Backfilling of the completed section of the pipeline shall be commenced as soon as possible in
order to prevent damage to pipes from external objects falling in to the trench. It is a good
practice to install marker tape at about 300mm above the pipe crown to protect the pipe from
future interference by others. The pipeline shall be protected by placing a 150mm thick
reinforced concrete bridging slab above the pipe in areas where minimum cover cannot be
maintained particularly on heavy traffic flowing highways. A minimum thickness of 150mm
sandwiched cushion of granular material shall be placed between the pipe crown and concrete
bridging slab.
The Contractor shall adjust the moisture content of the refill material either by drying out or by
adding water to assist the compaction of the materials where necessary. The backfill shall have
a uniform moisture content equal to or a little above the optimum moisture content recorded in
the Compaction Test during compaction. Backfill shall be compacted to a dry density value of
not less than 95% of the Laboratory Modified Proctor Density when tested in accordance with
these specifications. The Contractor shall carry out a minimum of one compaction test each
working day that back filling is taking place. The Contractor is advised to use clean river sand or
other clean granular material approved by the Engineer to obtain the required compaction in the
presence of wet conditions provided, the excavated materials or selected backfill materials
cannot be compacted to the required degree and the compaction work is held up.
(vi) Welding Process and Equipment
Experienced personnel shall supervise the welding process and the method of supervision shall
be agreed with the Engineer in advance. Each welder employed for the work shall be a qualified
person and shall have valid proof of his qualifications in this type of welding. The Contractor
shall submit method data in welding protocols or on data medium and other relevant particulars
to the Engineer for his approval prior to commencement of work.
The Contractor shall demonstrate to the Engineer prior to commencement of installation works
that he has adequate welding plant and equipment to perform the activities on continuous basis
with standby provision.
(vii) Butt Fusion Welding Procedure
Butt-fusion method jointing is a thermo-fusion process that involves the simultaneous heating of
the ends of two components that are to be jointed until a melt state is attained on each contact
surface. The two surfaces are then brought together under controlled pressure for a specific
cooling period and homogeneous fusion is formed upon cooling. The equipment for butt fusion
welding generally shall comprise the following components:
Generator for the supply of power to the heater plate, trimmer and hydraulic pump
Butt-fusion machine fitted with suitable size clamp shells, trimmer, heater plate, hydraulic
pump and timer
Pipe, Pipe support, covers and timer
Welding tent, Base board, Timer, Indelible marker pen, Air temperature thermometer
Cleaning material, lint free cotton cloth or piper towel
UNOPS – SDOC C5-9

External/Internal de-beading tool and Bead gauge

Digital thermometer with surface probe to check heater late
A comprehensive pre-welding check shall be undertaken prior to commencing of welding

operation. This investigation shall include functionality of generator and availability of fuel,
condition of trimming tool and hydraulic pump, cleanliness of heater plate and its sustenance of
correct temperature by connecting to power source for at least 20 minutes. The heater plate
shall be thoroughly washed with sufficient quantity of clean water to remove dirt deposits at the
start of each jointing session. Isopropanol or similar solvent shall be used for the removal of
grease and oily film with lint free material. Pipes and fittings to be jointed shall be of equal size,
same SDR and material.
The welding area shall be protected from unfavorable weather condition such as moisture, wind,
intensive UV radiation, temperature, etc. Welding operations shall be performed at any
temperature provided appropriate measures (such as preheating, tent-covering, heating) have
been taken to secure that the pipe wall temperature will be maintained. The joining areas of the
parts to be welded shall not be damaged or contaminated and it shall be cleaned thoroughly
free from dirt, oil, shavings, etc. All joints shall be executed so as to avoid any kind of stresses,
if possible and any stresses that may arise due to temperature differences between laying and
operating conditions shall be minimized.
Large deposits of dirt shall be removed by washing with water but finer dust particles may still
linger on the heater plate. Dummy joint shall be performed at the start of each pipe jointing
session or when the plate temperature has fallen below 130oC or change of pipe diameter in
order to remove fine particles. Two dummy joints shall be made for pipe size of diameter
greater than 180 mm. Dummy joint may be made using pipe cut pieces of the same size, SDR
value and material. This procedure may be discontinued after a full heat cycle and not
necessary to complete the entire joint. The non-stick coating of the heating element shall be
undamaged and it shall be cleaned with fluffless paper before commencing each welding
operation for optimum performance.
The pipe ends to be joined together shall be axially aligned and clamped in the butt fusion
machine in such a manner about 30mm to 50mm of each end is visible and the trimmer shall be
installed between the pipe ends. The misalignment of the joining areas to one another shall not
be more than the permissible degree of 0.1 x wall thickness on the pipe outside. The joining
surface of the clamped shall be machined in a plane parallel way and the maximum permissible
deviations from plane-parallelity at the joining surface are given below in the Table.
Pipe outside diameter Deviation

in mm in mm
< 400 ≤ 0.5
≥ 400 ≤ 1.0
Adequate care shall be taken to prevent movement of the pipes assembly during this process.
The pipes ends shall then be pressed against the trimmer so that to affect the trimmer blades to
cut the pipes ends smoothly. The trimming process shall be terminated by gradually reducing
the pressure in order to ensure even surfaces on both ends of the pipes on completion. Remove
loose shaving from the machine and component ends without touching the prepared surfaces.
The trimming process shall be repeated if the surfaces are not planed. Close the clamps and
check that there is no visible gap between the trimmed faces.
UNOPS – SDOC C 5 - 10
Open and then close the clamps and note the drag pressure needed to move the pipes together
using the hydraulic system. Drag pressure is the minimum gauge pressure required to
overcome the sliding fractional drag on the rams due to the operation of the machine and the
weight of the pipes/fittings being jointed. The trimmer shall then be withdrawn from the machine.
The drag pressure (in bar) must be assessed accurately prior to making each fusion joint and
must be added to the basic ram pressure values shown on the machine and shall be submitted
to the Engineer prior to jointing for his approval. Contractor is not permitted to perform fusion
welding without approval of the Engineer at site. Fully automated welding machines normally
perform this operation routinely.
The heater plate from its protective cover shall be removed and ensure it is sufficiently clean
and up to temperature. Insert the heater plate in the machine between the pipes ends so that
the welding faces of the parts to be jointed shall be aligned under pressure using hydraulic
system onto the heating element and then heated to the welding temperature of 200o to 240o C
under reduced pressure. Maintain this applied pressure until the pipe begins to melt and a
uniform bead of 2.3 mm is formed on each pipe end. Subsequent to initial bead up the pressure
in the hydraulic system shall be released so that pressure gauge registers between zero and the
drag pressure in order to control the bead growth during the heat soak time. Adequate
precaution shall be taken to prevent movement of pipe assembly and continue to sustain
contact with the heater plate. The heater plate shall be removed rapidly on satisfactory
completion of the heating process without touching the melted surfaces and the pipes ends
pressed sufficiently together in accordance with predetermined fusion pressure provided by the
manufacturer of the pipes or from the tables on the welding machine.
The pipe shall be removed from the welding machine when the weld has cooled to the ambient
temperature and the joint shall be undisturbed during the cooling period. The joint shall be
examined for cleanliness, uniformity and verify that the bead width shall within the specified
limits. The external bead and the internal beads if necessary shall be removed using suitable
de-beading tools. The beads and joint shall be numbered and coded using an indelible marker
pen. The beads shall be twisted at several positions and any splits seen at the beads imply
faulty jointing. This faulty joint shall be cut out from the pipeline and the jointing process
repeated until a satisfactory results attained. The strength of the joint at the butt fusion weld
shall at least be equal to that of the designed strength of the pipe.
(viii) Connection of PE to DI Flanges
The joining of PE pipe with ductile iron pipe can be achieved only with mechanical joints using
polyethylene flanged adaptors for main pipe such as SlimFlange, steel flanged converter, stub
ends with steel backing rings drilled to BS 4504 or fittings of the Viking Johnson or WASK type.
It is anticipated that the connection between PE pipe and DI flanged pipe shall be generally
accomplished with one of these joints.
5.1.2.4 Installation of Un-plasticized Polyvinyl Chloride (uPVC) Pipe and Fittings
Careful consideration must be given to the handling and storage of polyvinyl chloride pipe and
fittings. The pipe must be stored out of any direct sunlight. Extreme care shall be taken to
prevent any scarring or nicking of the pipe from bearing on sharp objects. Any pipe that has any
cut or bruise deeper than 10% of the wall thickness of the pipe shall be rejected and not be
used in the work. The section of pipe with such a cut shall be rejected in its entirety. The pipe
shall be stored in such a manner that no directs sunlight beat on the pipe but ventilation is
provided. Covering the pipe with a tarpaulin shall not be allowed and stacking shall not exceed
600 mm in height.
In normal ground, pipe shall be bedded in 150 mm depth of granular material and the same
material shall be placed either side of the pipe and compacted in 200 mm layers up to the
crown. Same material shall be placed over the pipe and compacted in two layers up to a depth
of 300 mm. In other types of ground, additional bedding types shall be used as shown in
relevant typical drawing. Sleeve pipes as shown on the drawing shall protect the uPVC pipe that
passed under or at the side of culvert.
The joints shall be of the push-in type and both spigot and socket ends of the pipes shall be
carefully cleaned before the rubber ring is set in place. The spigot shall then be covered with an
approved lubricant and the pipe pushed into the socket. Pushing the pipe into the socket shall
be done by barring against the opposite end of the pipe being installed. A wooden block or other
suitable device shall be used to prevent any damage to the socket against which the bar is
being pressed. No blocking will be allowed under the pipe and it shall bear evenly along its
entire length on the bedding material.
Cutting of the pipe shall be kept to a minimum and they shall be cut smoothly and perpendicular
to the axis of the pipe. Cuts shall be made with tools in conformance with the pipe
manufacturer’s recommendations. Cut ends shall then be tapered and beveled with a special
tool made for that purpose and the beveled end shall be exactly the same as the spigot end of
the pipe as manufactured at the factory.
Solvent weld joints for pipes of diameters 90 mm shall be made strictly in accordance with the
manufacturer’s recommendations and utilize only solvents furnished by the manufacturer. In
addition it will be necessary to snake the pipe so that on offset from true horizontal alignment of
30 centimeters in 30 meters of laying length will be provided. Care shall be taken to ensure that
the temperatures of both sections of pipe being jointed are the same. The Contractor shall use
solvent joints for pipes of diameter less than 90mm with the written approval of the Engineer.
Caution tapes (warning tapes) shall be installed in the pipe trench 500 mm above the crest of
the pipe for uPVC pipes of diameters 110 mm or more.
Concrete thrust and anchor blocks for uPVC pipes shall be provided with a minimum 2mm thick
polythene film or equally suitable material membrane to the satisfaction of the Engineer to
separate the fitting from the concrete. The warning tape shall be of polythene and shall have
performance details applicable to the 100 micron material of “Boddingtons underground warning
tapes”, or equivalent.
Minimum ultimate tensile strength at break (longitudinal and transverse) shall be

10MN/m2 as determined by BS 2782 method 301E.
Minimum Elongation shall be 300% (Longitudinal) and 350% (Transverse)
Shall be resistant to chemical attack from the ground conditions with pH ranging from 3.0
to 9.0.
The width of the tape shall be 100mm and blue in colour with the words printed “WATER PIPE
LINE BELOW – CAUTION!” on upper side of the tape in black letters printed in two rows at an
interval of 1m.
5.1.2.5 Installation of Galvanized Steel (GS) Pipe and Fittings
Installation of pipes, fittings and accessories shall be in conformance with the manufacturer’s
recommendations or as directed by the Engineer. Gibault or flange joints may be used if
necessary. All threads for screw joints shall be clean, machine cut, and all pipes shall be
reamed before erection. Each length of pipe as erected shall be up-ended and rapped to
dislodge dirt and scale.
Screwed joint shall be made up with good quality thread compound and applied to the male
thread only. After having been set up a joint must not be backed off unless the joint is
completely broken, the threads cleaned, and new compound applied. No close right and left
hand nipples shall be used. All nipples shall be of such length that the correct size of pipe
wrench can be used on them when in place.
At crossing over canals or ditches, the pipe shall be laid in accordance with the details and/or
construction method specified on the drawings or as directed by the Engineer. Pipe laid under
ditches shall be in accordance with the details shown on the drawings or as directed by the
Engineer. Pipe bedding shall be compacted for the entire length of the pipe, good alignment
shall be preserved and fittings may be used where necessary.
5.1.2.6 Installation of Reinforced Concrete (RC) Pipe and Fittings
The pipe shall be stored and handled in such a way to prevent any damage to the ends. Any
pipe with a broken bell or spigot shall not be used in the work. Neoprene gaskets shall be of the
proper circumference and fit tightly on the spigot.
The Engineer shall inspect all concrete pipes delivered to the site and any pieces rejected shall
promptly be removed from the site. Pipes not inspected by the Engineer shall not be
incorporated in the works. The Contractor shall make ample allowance of time to allow such
inspection.
Pipe shall be installed as soon as the excavation is completed to the normal grade of the bottom
of the trench. The Contractor shall immediately place granular material No.2 in the trench and
the pipe shall be firmly bedded in this material to conform accurately to the line and grade
shown. No blocking under pipe will be permitted.
Bedding is indicated on the drawings.
A depression shall be left in the bedding at the joint to prevent contamination of the rubber
gasket immediately before being forced home. Before the pipe is lowered into the trench, the
bell and spigot must be cleaned and free from dirt.
A vegetable lubricant furnished by the pipe manufacturer and harmless to the gasket shall
lubricate the “O-Ring” gasket and bell. The pipe shall be properly aligned in the trench to avoid
any possibility of contact with the side of the trench and fouling the gasket. As soon as the
spigot is centered in the bell of the previously laid pipe, it shall be forced home with jacks or
come-alongs. After the gasket is compressed and before the pipe is brought fully home, each
gasket shall be carefully checked for proper position around the full circumference of the joint.
The jacks or come-alongs shall be anchored sufficiently back along the pipeline so that the
pulling force shall not dislodge the piece already in place. Only a jack or come-along shall be
employed to force home the pipe smoothly and evenly and to hole the pipe while backfilling is in
progress. Under no circumstances shall crowbars alone be used or shall any motor driven
equipment be used.
As soon as the pipe is in place and before the come-along is released, backfill shall be placed
up to the mid diameter for at least one-half the length of the pipe. Not until this backfill is placed
shall the come-along be released. If any motion at joints can be detected, a greater amount of
backfill shall be placed before pressure is released.
All pipes are to be laid in an upstream direction unless otherwise approved by the Engineer for
each specific instance.
5.1.3 Exposed Piping
The Contractor shall furnish and install sleeves or wall casting for all pipes passing through masonry walls
and concrete floors or walls and concrete inserts for hangers and supports as soon as forms are erected
and before concrete is poured. Before setting these items, the Contractor shall check all and figures
which have a direct bearing on his pipe location and he shall be responsible for the proper location of his
pipes during the construction of the structures.
Piping shall be installed to the required lines and grades and as closely as possible to walls, ceilings,
columns and other structural parts so as to occupy the minimum of space and all offsets and fittings
required to accomplish this must be furnished. All dimensioned pipes and fittings shall be installed that no
stress or strain is created in the lines and associated equipment due to forcing parts into position.
Changes in direction shall be made using proper fittings. Piping shall run parallel and at right angles to
walls, unless noted otherwise. Temporary bracing and supports shall be provided to adequately support
the pipe during its installation and care shall be taken in placing piping to prevent damage to the
pipelining or pipe coating or to adjacent structures or equipment. All supporting piers and blocking shall
be in place before temporary supports and bracing are removed.
Flanged piping shall have a sufficient number of couplers and adapters to allow convenient removal of
piping. The Contractor shall furnish and place all inserts for the support of piping installed under this
section in masonry and in concrete forms before concrete is placed, unless otherwise permitted. Systems
shall be arranged with low points and drains to be provided with unions or union connections at low points
to permit draining. Fill connections shall also be provided on closed systems where required. Adequate
air vents shall be provided at high points in all liquid carrying pipes.
All exposed piping shall be rigidly supported by pipe hangers and supports specified hereinafter. All pipes
shall be sound and clean before installation. In case interference develops between piping and
appurtenances, the Engineer will decide which work is to be relocated regardless of which was first
installed. Upon completion of installation and testing, the Contractor shall paint all exposed piping in
accordance with the instructions of the Engineer. Where the pipe passes through wall sleeves, the
sleeves shall be caulked with sealing compounds recommended by the pipe manufacturer and approved
by the Engineer. Sealing compounds shall be applied in accordance with the manufacturer’s instructions.
5.1.4 Canal or River Crossing and Culvert Crossings
The Contractor shall furnish all labour, equipment and materials and perform all incidental work required
to install canal or river crossings and culvert crossings as shown on the drawings or as specified or as
otherwise directed by the Engineer. The Contractor shall follow the requirements set out in Section 1 of
this Specification for canal or river crossings using existing bridges.
(1). General Conditions
The Contractor shall dig test pits near the bridge and/or the bank of the canal prior to installation
of pipe crossing the canal. In the event of underground structures and/or utilities are not in the
same locations as indicated on the Drawings that may cause changes in the pipe routing,
position of form of pipe support structures and other related works, then the Contractor shall
prepare drawings showing detail of the changes and submit them to the Engineer for approval.
The Contractor shall pursue the directions of the Engineer on this matter and any damage
resulting from not carrying out said direction including the costs in changing the method of
construction of the approach pipe laying shall be borne by the Contractor.
Welding of steel pipe shall conform to AWWA C206 and the steel used for pipe supports and
incidental works of canal crossing shall be of structural steel. Concrete thrust blocks and
supports shall be constructed at fittings or bends where indicated on the Drawings or as
directed by the Engineer.
(2). Construction
The Contractor shall submit the proposed method and details of the construction to the
Engineer for his approval. Approval of such details shall not relieve the contractor from the
responsibilities under the Contract. The Contractor shall take extreme care to protect bridges,
surrounding structures and utilities from damage. Vehicular and pedestrian traffic shall be
maintained at all times as well as utility services. Costs or charges resulting from damage
thereto shall be borne by the Contractor.
The Contractor shall provide support to the pipes with proper concrete structures where pipe
trenching is not practical or pipes are to be installed in swampy areas. The installed pipe shall
be levelled as shown on the Drawings and an air valve shall be installed at the highest point of
the pipe or at the end point of the pipe or at the tail water end as shown on the Drawings.
Necessary trench cut off walls and rubble pitching shall be provided for crossing of pipeline
outside of the culvert and under the invert level as shown in the drawing.
5.1.5 Pipeline Marker Tape
The contractor shall supply and install marker tape for all pipelines to be laid under this contract in
compliance with the provisions in this clause. The polyethylene detectable warning marker tape shall be
resistant to acid and alkaline. The tape shall be blue in colour and clearly marked in black lettering with
“CAUTION – WATER MAINS BELOW” in English with a maximum repeat distance of not more than 1 m.
The width of the marker tape shall be 150mm or the diameter of the pipe, whichever is smaller and shall
consist of all accessories necessary for installation at the chambers, splicing, junctions etc. Methods of
joining and terminating the tape to enable a low resistance connection to be made to the aluminium foil /
wires shall be in accordance with the manufacturer’s instruction. Electrical connection points shall be
made at each chamber along the pipeline route. The warning tape shall have a minimum strength of 125
kg/cm2 in the longitudinal direction and 105 kg/cm2 transversely.
The minimum thickness of the marker tape to be provided for metal pipes such as ductile iron, steel, etc.
shall be 0.5mm composed of 0.4mm thick polyethylene base layer and 0.1mm thick of polyethylene
sealing layer. However, the thickness of the marker tape to be provided for non-metal pipes such as
polyethylene (PE), polyvinyl chloride (uPVC), etc. shall be not less than 0.575 mm composed of
polyethylene sealing layer of 0.1 mm, aluminium foil of 0.075 mm and base layer of polyethylene 0.4 mm.
The additional metal aluminium foil for PE and uPVC pipes marker tapes shall be provided to locate these
pipes from the surface with a metal detector in addition to act as a warning media during excavation
activities by others. The metallic conductor(s) shall be either aluminium foil having a width of not less than
50 mm and a thickness of not less than 0.075 mm or stainless steel wires. The aluminium foil for metallic
conductor shall contain not less than 95% pure aluminium. The aluminium foil / stainless steel wires shall
be totally enclosed within the polyethylene laminate such that the edges of the foil are totally protected
against aggressive soil corrosive action. The aluminium foil / wires shall be easily detectable from the
ground surface with the aid of a buried cable locator.
The marker tape shall be placed in position during backfilling of the completed pipeline trench at a depth
of 300mm above the pipe crown unless specified otherwise in the drawings with the longitudinal
centerlines of the pipeline and marker tape lies on the same vertical alignment. The cost of supplying and
laying of the warning tapes shall be included in the relevant pipe laying item in the bill of quantities.
Notwithstanding the above requirements, warning marker tapes shall not be provided for yard piping
within the treatment plant compound, intake site, storage reservoir sites and booster pumping station
compounds.
SECTION - 5.2 CONNECTIONS TO EXISTING MAINS
5.2.1 General
(1). Scope of Work
The Contractor shall supply all labour, tools and equipment obligatory to connect the new
pipelines to the existing pipes that have been constructed previously in accordance with the
drawings and specifications and as may be directed by the Engineer.
(2). Submittals
The Contractor shall excavate at the point of connection and inspect the existing facilities to
determine the material type and make necessary records. On completion of this data collection,
the hole shall be backfilled and the surface temporarily restored with asphalt pavement. Based
on the field data, the Contractor shall prepare and submit shop drawings showings the method
proposed for making the connection. Field data collected shall be clearly indicated on the shop
drawings.
Generally the connections shall be made under dry unless a wet tap is specified. The Contractor
shall co-ordinate his pipe connection activities and pressure testing with the relevant operational
unit of UWC so that interruption of service to consumers is minimized.
The Contractor shall incorporate as part of the shop drawings a detailed plan for shutting down
of existing water supply pipelines to facilitate interconnections in dry condition. The Contractor
shall determine the locations of all isolating valves required to be shut down and check their
operational functionality. The Engineer shall provide necessary assistance in developing this
plan.
(3). Materials
All material including pipe adapters used to make the required connections shall be in
accordance with the applicable standard of similar works.
5.2.2 Execution
Connection of the new pipeline to the existing pipelines shall be made as specified on the drawings. The
Contractor shall clean up the inside of the existing pipes prior to the connection to the new line. The
Contractor shall be fully responsible for testing and disinfection of the portion of existing pipeline from the
point of connection to the extent that has been affected by the connection work as instructed by the
Engineer.
Prior to any connection work to the existing service lines, the Contractor shall notify the Engineer of his
intention to commence this particular work. No connection work shall be commenced unless an approval
by the Engineer has been given in writing. The work program of the Contractor has to be approved by the
Engineer before starting connection activities.
5.2.3 Testing
All cross connections to the existing mains or valves shall be executed prior to the hydrostatic pressure
testing of the new water mains and they shall be included as part of testing components.
SECTION - 5.3 INSTALLATION OF VALVES & MARKER POSTS
5.3.1 General
(1) Scope of Work
The Contractor shall supply all labour, equipment and material where required to install valves,
fire hydrants and marker posts as well as to construct valve chambers and surface boxes as
shown on the drawings and as specified hereinafter. This work includes: surface breaking;
excavation and backfilling; sheeting and bracing; on site forming; installation of pipes, fittings,
valves, fire hydrants and appurtenances; installation of miscellaneous metalwork, surface
restoration and other work needed to complete the valve boxes.
Most of the components of work involved in this connection are stipulated somewhere else in
this Specification and the Contractor is advised to consult such sections for further details. This
section particularly consolidates a description of the work required under this item.
(2) Submittals
The Contractor shall prepare and submit a shop drawing for each installation. The shop
drawings shall be based on the schematic arrangement shown on the drawings and include the
dimensions of piping, appurtenances and other equipment to be installed and shall extend to the
limits of the installation shown on the drawings or to the limit of special pipe construction. All
supports, clearances and materials to be installed shall be shown.
5.3.2 Materials
The construction materials such as cement, aggregate, water, admixture, reinforcing steel, concrete, form
work, shall be in accordance with the provision of Chapter 3 “Concrete Works”.
5.3.3 Location of Installation
(1) Fire Hydrants
The location of the fire hydrants shall be either under the pedestrian walkway or under the
shoulder of the road, but shall not be under the carriageway. The Engineer before installation
shall approve the location.
(2) Valves
The valves shall be located at a distance reasonably away from the road junctions so that the
installation is not adversely affected by future road widening or surfacing by the road
maintenance authorities. The Contractor shall obtain the approval of the Engineer before
installation of any valve.
5.3.4 Execution
(1) Underground Utilities Interference
The Contractor shall excavate test pits where existence of underground utilities are shown on
the drawings or anticipated near the proposed location of the new installation to ensure that they
shall not interfere with the construction of the structure. Proper precautions shall be instituted to
protect the existing underground utilities in order not to disrupt essential services to the general
public.
(2) Manhole Frame and Cover
Manhole frame shall be set with the top conforming to the grade of the pavement or finished
ground surface as indicated on the drawings or as directed by the Engineer. Frames shall be
set in full bed of mortar.
(3) Valve Box
Valve boxes shall be constructed with the top of cover lower by 0.2m from the grade of the
pavement or finished ground surface or as indicated on the drawings or as directed by the
Engineer. The manhole frame and cover shall be raised with its top conforming to the grade of
the pavement or finished ground surface.
5.3.5 Installation of Marker Posts
Marker Posts shall be installed at the locations of all valves and meters of the distribution pipelines,
transmission mains and at the location of fire hydrants. The type, depth, location and diameter of the main
shall be indicated as specified in the relevant drawing for the specified sizes of valves and pipelines. The
Contractor shall obtain the approval of the Engineer regarding the location for installation of marker posts
and also obtain the permission from the relevant authorities for their installation.
SECTION 5.4 - TESTING & DISINFECTION
5.4.1 General
(1). Scope of Work
The Contractor shall furnish all labour, equipment, materials and metering device required for
the cleaning, pressure and leakage testing, and the disinfection of the finished pipelines. The
finished pipeline shall include the pipes, fittings, valves, fire hydrants and all other
appurtenances that are constructed under this Contract. The Contractor shall provide the
facilities to convey water from its source as designated by the Engineer to the place where it is
required and shall install the necessary metering device. All cleaning, testing and disinfecting
operations shall be performed in the presence of the Engineer.
The delay in testing and commissioning of a pipeline shall not be permitted due to late delivery
of valves to the site. In such instances, the Contractor shall supply and install spool or make up
pieces so that testing may proceed and the valves shall be installed later in a manner
acceptable to the Engineer.
(2). Standard Specification References
The following standards are referred to in this respect for adherence.
AWWA C600 Standard for Installation of Ductile-Iron Water Mains and their
Appurtenances
AWWA C601 Standard for Disinfecting Water Mains
(3). Submittals
The Contractor shall submit as part of his shop drawings a sketch for each section of pipe to be
tested. The sketch shall show the section schematically in profile and shall contain a sequence
of operation to be followed during the test such as test pressure, observations and closing of air-
valves, blow-offs and other appurtenances; point of water filling and point of monitoring
pressure.
5.4.2 Colouring Tests for Welding
The colouring test shall be performed at each welding joint covering entire welded circumference and
examined for any defects or incompletion in accordance with JIS Z2343 or equivalent. The Contractor
shall repair any defect or pinhole detected by the colouring test to the satisfaction of the Engineer and the
test shall be repeated to ensure that the repair work has been satisfactorily carried out. The Contractor in
the presence of the Engineer shall carry out all such tests. The faulty welds shall be rectified in
accordance with the instructions of the Engineer at no extra cost to the Employer.
The Contractor shall nominate a qualified chief supervisor for field tests of steel pipes and he shall be fully
responsibility to perform and supervise the field tests of steel pipes. All expenses related to said testing
including expenses for equipment, tools, materials, labour, reporting, and any other connected works
shall deemed to be included in the rates of payment items for installation of steel pipes.
5.4.3 Field Hydrostatic Pressure Test
Hydrostatic pressure test procedure for the pipeline shall be as specified in Section 4.1 of AWWA C600
that shall be not less than 1.5 times the maximum working pressure. The working pressure shall be of
water column based on the elevation of the lowest point in the pipeline under tests and corrected to the
elevation of the test gauge for all pipe sizes. The pressure tests shall be conducted on the pipelines in
sections after the trench is backfilled except the pipe joints wherever possible, but before restoration of
the road pavement. The selected stretch of the pipeline for testing which is not more than a kilometer
shall be securely anchored by constructing all thrust and anchor blocks before subjected to testing.
The pipelines shall be thoroughly flushed out with water prior to performing pressure testing. The pipeline
shall be prepared for testing by closing all valves and hydrants; placing substantial stops and bulkheads
at openings, opening of air valve assemblies and fitting air release taps at all other high points along the
pipeline. These taps shall later be removed after completion of the testing and disinfection and unless
otherwise specified replaced with permanent plugs.
The pipeline shall be gradually filled with water allowing for all air pockets to be released until the pipe is
completely filled and attain the required working pressure at which condition it shall be allowed to stand
for 24 hours. The Contractor shall rectify any apparent defects in the pipeline at this stage. The complete
removal of entrapped air in the pipeline shall be verified by the Contractor by adding a measured quantity
of water at the filling point and measure outflow at remote points of pipe being tested. The Contractor
shall install suitable taps for this purpose provided the remote points of pipeline do not contain convenient
points to measure outflow. The hydrostatic pressure of the pipeline shall then be raised to the level of test
pressure and maintained it for two (2) hours duration. Any defective pipe, fittings, joint, valve or hydrant
shall be removed and replaced and the test shall be repeated until to the satisfaction of the Engineer.
In the case of PE pipes, all welding joints shall be completed and cooled down (at least 1 hour after last
welding process) prior to pressure testing. The pressure test shall be performed according to relevant
standards (DIN 4279 or similar) and the imposed maximum test pressure shall be 1.5 x Nominal Pressure
of the pipe. Special care shall be taken during testing since there will be a pressure decay even in a leak
free system due to visco-elastic (creep) response of the flexible nature of the material. The testing
procedure developed by WRc “Manual for Polyethylene Pipe Systems for Water Supply” shall be
employed for this purpose. No pressure drop shall be allowed at least for 10 minutes during the test
period.
5.4.4 Field Leakage Test
Leakage tests procedure for the pipeline shall be as specified in Section 4.2 AWWA C600 and this test
shall be conducted after the satisfactory completion of hydraulic pressure test. The pipeline shall be
subjected to the same test pressure as stated in the preceding paragraph for a continuous duration of two
(2) hours and the amount of water injected during this period in order to maintain the constant test
pressure shall be taken as the quantity leaked. The allowable pipeline leakage shall be less than 2.3 litres
per mm-pipe diameter per km-length for a period of 24 hours as presented by the formula given below.
Q
----------------- * 24 < 2.3
D*L*H
Where:
Q: Amount of leakage in litres
D: Diameter of pipe in millimeters
L: Length of pipeline in kilometers
H: Duration of leakage test in hours
The Contractor shall locate and repair or replace the defective materials or joint to the satisfaction of the
Engineer when any pressure test of laid pipeline revealed a leakage exceeds the specified limit. The test
shall be repeated on the rectified section of the pipeline until extent of leakage falls within the permitted
allowance.
5.4.5 Disinfection
(1). Swabbing
The Contractor shall on the instructions of the Engineer demonstrate that entire length of
pipeline is free from any obstruction on completion of pipe laying and satisfactory pressure
testing in accordance with the relevant Clauses in the Contract. This process shall be performed
by means of passing through the pipelines a polyurethane foam swab of approved grade in
accordance with the procedure setout below.
Impediment free to any portion of the pipelines shall be established in sections between entry
and exit points. The locations of the permanent swabbing points are indicated on the Drawings.
Temporary swabbing points shall be provided in the distribution system by insertion of tees and
valves, which shall be removed on completion and replaced by short lengths of straight pipe.
The swab shall be introduced at the start of the operation through the entry point at the
upstream end of the selected section of the pipeline by means of a tee provided, keeping the
isolating valves on branch mains closed. The isolating valves on either side of the entry point
shall be opened sufficiently to flood the entry tee containing the swab and the sluice valve on
the entry tee shall then be closed. By opening the isolating valves on either side of the entry
point the swab will be free to travel along the pipeline towards the downstream exit point.
The theoretical loss of head between the entry and the exit points located at either end of the
section shall previously have been determined by the Engineer for a flow of water, which shall
cause the swab to travel through the section at a suitable predetermined velocity. This flow and
the corresponding required velocity of the swab shall be controlled by throttling of valves at the
exit point or at hydrants or washouts.
Washouts or hydrants downstream of swabs shall be closely monitored for any rubbish, silt,
debris or other extraneous matter that may be discharged during the passage of the swab along
the pipeline. Demonstration of any section shall be repeated as required by the Engineer until a
satisfactory result has been realized. The Contractor shall provide all transport and labour
required to establish a pipeline that is free from obstructions.
Diameters 300 mm and greater
Visible dirt and debris should have been removed either manually or by the use of cleaning pigs
before testing. The Contractor shall flush out and cleanse the pipelines after the pipelines have
been completed and pressure tested satisfactorily as herein specified. Pipelines shall be
cleansed in sections and this shall be carried out by passing polyurethane foam swabs through
the pipeline. The swabs material shall be to the approval of the Engineer and water for passing
swabs shall be made available by the Employer.
Diameters less than 300 mm
Pipelines shall be cleansed in sections by flushing with potable water provided by the Employer
for a period of time determined by the Engineer’s representative. Cleansing of any section shall
be repeated as required by the Engineer’s representative until a satisfactory result has been
realized. The Contractor shall supply all necessary equipment for the cleansing and sterilizing
operations including sufficient swab and swab detectors. Swabs shall be of suitable grade and
dimensions appropriate to the pipelines being cleansed and to the approval of the Engineer.
Swabs shall be passed through pipelines at speeds of between 0.2 and 0.4 metres per second
to obtain the best cleaning result with the minimum number of passes. The Contractor shall be
wholly responsible for repairing of the lining of the pipes, if it is apparent from the debris
collected by the swab that damage to the lining has occurred, to the satisfaction of the
Engineer’s representative. The cost of the initial sampling analyses and preparing reports on the
bacteriological quality of water shall be borne by the Employer but, in the case of the initial
reports be unsatisfactory the cost of any subsequent sampling analyses and preparing reports
shall be borne by the Contractor. The cost for performing this operation shall be allowed in the
appropriate item in the bill of quantity.
(1). Disinfection
All new pipelines that are intended for conveyance of potable water shall be disinfected with
chlorine and a satisfactory bacteriological analysis of the water certified in accordance with
AWWA C601 shall be submitted to the Engineer before the pipeline being placed into services
or certification of completion by the Engineer whichever occurs earlier.
The amount and concentration of chlorine solution applied shall ensure a minimum dosage of
50 mg per litre introduced into the pipelines as directed by the Engineer. The residual chlorine at
the end of pipeline shall not be less than 25 mg per litre after a contact period of 24 hours. The
system shall then be flushed out with clean water until the residual chlorine is diluted to a value
less than 0.75 mg per litre but not less than 0.25 mg per litre. The point of application of the
chlorination agent is normally at the beginning of the pipeline through a corporation stop
insertion on the top of the laid pipe and the point of withdrawal (normally by blow-off) is at the
opposite end of the line.
In the event of initial treatment failed to achieve the desired results stipulated previously, the
chlorination procedure shall be repeated until a satisfactory results are obtained. The Contractor
shall dispose of the water used in the pipeline testing and disinfecting operations without
causing any harm to adjacent property.
5.4.6 Connection of Pipes and Fittings
Prior to commencement of Test on Completion of the entire system, the Contractor shall connect each
other of hydrostatically testified individual sections of pipelines including valves and fittings. The test on
completion shall be arranged in the presence of the Engineer’s Representative. The minimum duration of
test shall be 48 hours or as decided by the Engineer depending upon the locality.
The transmission systems shall be connected to their inlet and outlet ends and the installed delivery
mechanism such as pumps shall be utilized for testing. All surge protection and safety equipment shall be
functional fully with their desired outputs. Any faults encountered during testing shall be rectified
immediately and repeat the test proceedings.
Distribution system shall be tested for their designated zonal boundaries or their sub zonal boundaries
where appropriate. Systems shall be connected to their intended inlet sources and allowed to carry the
full design discharges by means of end free delivery either through scour-valves or section valves where
appropriate. Any faults encountered during testing shall be rectified immediately and repeat the test
proceedings.
.
Valves, Hydrants, meters and control devices installed in both transmission and distribution systems shall
be demonstrated beyond doubt in operation for their intended purpose and to its design efficiencies and
accuracies. Engineer shall satisfy test on completion in accordance with the manufacturers’
recommendations as per his catalogue or shop drawings.
SECTION - 5.5 PIPE JACKING FOR RAILWAY CROSSING
5.5.1 Scope of Work
The Contractor shall furnish labour, materials, equipment and incidentals to install the encasement pipe
by pipe jacking for railway crossing in accordance with the drawings and as specified herein. The work
shall include supply of driving pipe with jointing materials, construction of driving and arrival shafts, pipe
driving and incidentals to complete placing of the encasement pipe under the utilities at the locations as
indicated on the drawings.
5.5.2 General Requirements
Construction method applicable to the pipe driving under this contract shall be open type. Excavation
may be done either by manual or by mechanical methods.
Special measures for pipe driving such as ground treatment and/or use of intermediate jacks are not
indicated on the drawings but may be incorporated in the driving work by the Contractor. The
Contractor's attention is directed to the fact that there will be a large thrusting force required for the pipe
driving operation and that the earth behind the driving shaft must safely withstand the thrusting force
during the operation. The Contractor shall be responsible to there in force the original soil to obtain
sufficient bearing capacity for the jacking force if required, and for this purpose, the Contractor shall carry
out additional subsoil investigation as necessary. All expenses due to this improvement shall be the
responsibility of the Contractor.
Prior to the construction work, the Contractor shall investigate existing subsurface structure and utilities
located in and around the construction site so as not to damage those facilities during all stages of
construction activities. The Contractor shall make a continuous measurement and record of the level of
the existing ground, road surface and railway line at all stages of driving operation.
Any intended change of construction method during driving operations shall require the Engineer's
approval. The Contractor shall liaise with the Railway Authority throughout the pipe jacking work under
the railway lines and comply with all their requirements.
5.5.3 Driving Pipe
Driving pipe (encasement pipe) shall be steel or ductile iron pipe and the pipe material component and
fabrication shall comply with the standard specifications. Wall thickness shall not be less than that shown
on the drawings. Lining and exterior coating will not be required.
5.5.4 Driving and Arrival Shaft
Driving shafts shall be sized so that all equipment needed for the driving operation can be reasonably
accommodated in the shaft, sand filling, jointing of pipe and other works in the shafts can be safely done.
Each driving shaft at the bottom shall be provided with dewatering sumps and pumps to maintain the
shaft dry throughout the driving operation. Each driving shaft shall also be equipped with a crane for
unloading of pipe and driving equipment and for removal of excavated soil.
Arrival shafts shall be sized so that removal of cutting edges and pipe connections in the shafts can be
satisfactorily accomplished. Unless otherwise directed by the Engineer, construction of arrival shafts
shall be delayed until driving operation has been nearly finished.
5.5.5 Cutting Edges
Irrespective of the construction methods to be used by the Contractor, cutting edges shall be designed to
withstand against the required driving force and anticipated earth pressure. Each cutting edge shall be
designed to integrate a reasonable number of jacks of controlling of pipe alignment and grade during
driving operation.
Cutting edges shall have the same outside diameter as that of the steel-encasing cylinder of pipe for
driving.
5.5.6 In-Pit-Based Jacks
The total number of in-pit-based jacks shall be determined on the basis of jack output equal to 70 percent
of the rated jack pressure. The rated pressure of the jack shall not be less than 400-kg/sq.cum and
jacking stroke shall not be less than 500 mm.
5.5.7 Installation of Casing Pipe
The Contractor shall take all necessary steps to ensure that the casing pipe is driven to the proper
alignment and grade. The method of welding for steel pipe casing shall be same as that used for field
welding of steel pipe and fittings. Approved coat of painting equivalent to that of shop applied coating
shall be applied across the joints subsequent to the welded joints have been inspected and approved by
the Engineer. The ductile iron pipe shall be jointed as shown on the drawings.
The casing pipes shall be jacked progressively as they are jointed and properly positioned. The space
between the pipeline and the casing pipe shall be filled with rammed sand or very weak grout thereafter
and it could be removable later for maintenance purposes.
5.5.8 Submittal of Shop Drawings and Reports
Prior to commencement of construction work, the Contractor shall submit to the Engineer shop drawings
containing at least the following:
o Results and analyses of soil investigation.

o Construction method and sequence in detail.
o Design calculations to determine the wall thickness of the steel casing pipe.
o Drawings showing full details for dimensions of steel casing pipe for driving including pipe
joint and cutting edge.
o Drawings showing full details of driving and arrival shafts.
o List of equipment to be used.
The shop drawings shall be submitted for each railway crossing work. The Contractor shall commence
no construction work until the Engineer has approved the shop drawings.

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PIPELINE INSTALLATION

CHAPTER 5 – PIPELINE INSTALLATION

SECTION 5.1 - PIPE LAYING 1

UNOPS – SDOC ToC - I

CHAPTER 5 PIPELINE INSTALLATION

SECTION 5.1 - PIPE LAYING

5.1.1 General Requirements

UNOPS – SDOC C5-1

The following applicable standards are referred to various pipe materials:

ISO 4482 Asbestos-Cement Coating – Guide for laying

5.1.2 Installation of Pipe and Fittings

5.1.2.1 Installation of Ductile Iron (DI) Pipe and Fittings

UNOPS – SDOC C5-2

(i) Concrete Protection of Pipe

(ii) Push-in Joints and Restrained (Self Anchored) Joints

(iii) Flanged Joints

(iv) Slip-on Coupling, Collars and Flange Adapters

(v) Deflection of Pipeline

UNOPS – SDOC C5-3

Nominal Diameter Maximum Allowable Deflection (degree)

80 to 200 5.0 5.0

(vi) Cutting of Pipes

(viii) Protection of Joints

UNOPS – SDOC C5-4

5.1.2.2 Installation of Steel Pipe (SP) and Fittings

(i) Coal Tar Enamel Coating (Underground Buried pipe)

UNOPS – SDOC C5-5

(ii) Epoxy Painting (Above-ground Exposed Pipe)

(iii) Cement Mortar Lining

5.1.2.3 Installation of PE Pipe and Fittings

(ii) Transportation and Storage

UNOPS – SDOC C5-6

UNOPS – SDOC C5-7

(iv) Installation of Pipes

UNOPS – SDOC C5-8

(vi) Welding Process and Equipment

(vii) Butt Fusion Welding Procedure

UNOPS – SDOC C5-9

 External/Internal de-beading tool and Bead gauge

A comprehensive pre-welding check shall be undertaken prior to commencing of welding

Pipe outside diameter Deviation

(viii) Connection of PE to DI Flanges

5.1.2.4 Installation of Un-plasticized Polyvinyl Chloride (uPVC) Pipe and Fittings

 Minimum ultimate tensile strength at break (longitudinal and transverse) shall be

5.1.2.5 Installation of Galvanized Steel (GS) Pipe and Fittings

5.1.2.6 Installation of Reinforced Concrete (RC) Pipe and Fittings

Bedding is indicated on the drawings.

5.1.3 Exposed Piping

5.1.4 Canal or River Crossing and Culvert Crossings

(1). General Conditions

5.1.5 Pipeline Marker Tape

SECTION - 5.2 CONNECTIONS TO EXISTING MAINS

(1). Scope of Work

SECTION - 5.3 INSTALLATION OF VALVES & MARKER POSTS

(1) Scope of Work

5.3.3 Location of Installation

(1) Fire Hydrants

(1) Underground Utilities Interference

(2) Manhole Frame and Cover

(3) Valve Box

5.3.5 Installation of Marker Posts

SECTION 5.4 - TESTING & DISINFECTION

(1). Scope of Work

External/Internal de-beading tool and Bead gauge

Minimum ultimate tensile strength at break (longitudinal and transverse) shall be