IRRIGATION SYSTEMS - TECHNICAL SPECIFICATIONS VOLUME III

19. DI PIPES (SECTION 02640)

19.1.Part 1 General
19.1.1 Scope
A. This section of the specification gives the requirements for Ductile Iron (DI
pipes and fitting materials, installation and testing.

19.1.2 Related Documents

A. The following sections of the specification shall be read in conjunction with this
section.
Section 01300 Submittals
Section 01400 Quality control
Section 01600 Materials and equipment
Section 02222 Excavation
Section 02223 Backfilling
Section 02225 Trenching
Section 15121 Pipe Expansion Compensation
Section 15245 Vibration Isolation
Section 15140 Pipe Supports

19.1.3 Standards
A. All activities relating to this section of the specification shall comply with the
following or approved equal standards.

BS EN 545 Ductile iron pipes, fittings and their joints for water pipelines.
Requirements and test methods
ISO 2531 Ductile iron pipes, fittings, accessories and their joints for
water applications
BS 10025 Hot rolled products of structural steels
BS EN 681-1 Elastomeric seals – Materials requirements for pipe joint seals
used in water and drainage applications. Vulcanized rubber
BS EN 1092-2 Flanges and their joints. Circular flanges for pipes, valves,
fittings and accessories, PN designated. Cast iron flanges
BS EN 1563 Founding spheroidal graphite cast iron
EN 14901 Ductile iron pipes, fittings and accessories. Epoxy coating
(heavy duty) of ductile iron fittings and accessories.
Requirements and test methods
EN 15655 Ductile iron pipes, fittings and accessories. Internal
polyurethane lining for pipes and fittings. Requirements and
test methods
ISO 8180 Ductile iron pipelines. Polyethylene sleeping for site application

PAGE 99
DIVISION 02-SECTION 02640 FIRST EDITION -DECEMBER 2016
IRRIGATION SYSTEMS - TECHNICAL SPECIFICATIONS VOLUME III

BS 6920 Suitability of non-metallic products for use in contact with water

intended for human consumption with regard to their effect on
the quality of the water Methods of test.
19.1.4 Submittals

19.1.4.1 Products and Materials Approval.

A. In order to verify compliance with the specification the Contractor shall
submit information for all products and materials used in the Works to the
Engineer for approval sufficiently in advance of their use in accordance
with the Contract programme allowing for ordering and approval times.
Reference shall also be made to Section 01600 of the specification on
products and materials approval. Information to be submitted shall
comprise but not necessarily be limited to:

i. Manufacturers name.
ii. Suppliers name.
iii. Pipe diameters and pressure ratings.
iv. Manufacturer’s technical data.
v. Support details.
vi. Connection details.
vii. Manufacturer’s quality control and test procedures.
viii. Manufacturer’s hydraulic test reports.
ix. Manufacturers guarantee.
x. Joint materials and gaskets.
xi. Detailed information on coatings.
xii. Certificate of compliance of the used nonmetallic materials with
requirements of the BS6920.

19.1.4.2 Method Statements

A. The Contractor shall submit method statements to the Engineer for
approval 4 weeks in advance of commencing the site activity in
accordance with Section 01300 of the specification. These shall comprise
but not necessarily be limited to:

i. Procedures for handling, storage and installation of pipes

including cleaning and repair.
ii. Hydrostatic testing procedures.
iii. A detailed statement for local application of coatings.

19.1.4.3 Working drawings.

A. The Contractor shall submit drawings to the Engineer for approval in
advance of commencing the site activity in accordance with Section 01300
of the specification. These shall comprise but not necessarily be limited to:

i. Drawings of the pipes, fittings, joints, pipe specials and the assembly
thereof.

PAGE 100
DIVISION 02-SECTION 02640 FIRST EDITION -DECEMBER 2016
IRRIGATION SYSTEMS - TECHNICAL SPECIFICATIONS VOLUME III

19.1.5 Quality Control

A. Prior to dispatch of any product and/or material from source the Contractor
shall notify the Engineer in writing in sufficient time to allow the Engineer the
opportunity to inspect and test the product and/or material prior to delivery in
accordance with Section 01400 of the specification.

B. Products and materials shall be from a manufacturer/supplier who operates a

quality system which is registered to ISO 9000 series or approved equal.

C. Manufacturers shall have a minimum of 5 years manufacturing experience with

the type of pipes and fittings being proposed.
D. To allow the Engineer to inspect the Works the Contractor shall give the
Engineer a minimum of 24 hours’ notice of carrying out the following activities
on site.
i. Installation of pipeline.
ii. Hydrostatic testing of pipeline.
iii. A detailed statement for local application of coatings.

19.1.6 Delivery, Storage and Handling

A Delivery, storage and handling of products and materials shall be in
accordance with the manufacturer's recommendations, Section 01600 of the
specification and the following provisions.
i. Delivery storage and handling shall at all times be performed in a manner to
avoid product damage.
ii. Pipes and fittings shall not come in contact with any sharp projections that
may cause damage to the pipes and fittings during transportation loading
and unloading. Ensure that pipes and fittings are well secured during transit
and adequately supported along their length. Do not allow pipe to overhang
the end of a vehicle during transportation.
iii. Ensure that pipes and fittings are protected from damage while being lifted.
The hooks used shall be padded. Use only nylon or reinforced fabric slings
and ropes if they are in direct contact with pipes and fittings.
iv. Store pipes and fittings on a flat level area and raised above the ground on
timber bearers. Provide timber bearers at spacing recommended by the
pipe manufacturer.
v. Store joint materials and gaskets in a well ventilated place free from
exposure to sunlight and in their original packings until they are needed.
vi. The Contractor shall visually inspect all products upon delivery to site and
report any damage to the Engineer.

 Any products damaged during delivery, storage and handling shall be

marked by the Contractor and set aside.
 Proposals for repair of any damaged products shall be submitted in
writing to the Engineer for approval.
 Any damaged products deemed unsuitable for repair by the Engineer
shall be removed from site and replaced.

PAGE 101
DIVISION 02-SECTION 02640 FIRST EDITION -DECEMBER 2016
IRRIGATION SYSTEMS - TECHNICAL SPECIFICATIONS VOLUME III

19.2. Part 2 Products

19.2.1 General Requirements

A. Pipework and fitting materials and coatings shall be suitable for their intended
use, shall be internally chemically resistant to the conveyed fluid and any
gasses produced by the fluid and shall externally be chemically resistant to
the surrounding environment.
B. Pipework and fittings shall be manufactured to the requirements of BS EN 545
or ISO 2531 as appropriate.
C. Class designation of the socket spigot pipes shall be K9 or C30 for pipes in
range from DN150 to DN300 and C40 for pipes in range from DN300 to
DN600.
D. Class designation of the double flange pipes and flanged fittings with integrally
casted flames shall be K12.
E. Class designation of the double flange pipes with welded flanges shall be K9
for body and K12 for flanges.
F. Flanges shall be PN16 to BS EN 1092-2. Face of the flanges shall be at right
angle to the directional access and shall be concentric with it. Flanges of the
fittings shall be integrally casted and rotatable. Welded flanges shall be
permitted only in case of double flanged pipes.
G. Flanged pipe and fittings shall be factory produced and shall not be fabricated
on site.
H. Bolts, nuts, washers, anchor plates and all fixings shall be of stainless steel
grade 316 and shall remain unpainted.
I. Contact between dissimilar materials shall be prevented by the use of suitable
washers, bushes and bedding pads so as to avoid galvanic reactions.

19.2.2 Wall, Floor, Slab and Roof Penetrations

A. Pipework passing through concrete walls, floors, slabs and roofs shall have
integrally cast paddle flanges as shown on the drawings and shall provide a
watertight installation. The coating to the paddle flange shall be similar to that
of the pipe/fitting.

B. Thrust/anchor flanges shall be used were pipework or fittings are cast into walls
etc. and shall be designed to restrain the installed equipment. Thrust/anchor
flanges shall be integrally cast or factory welded onto the pipe piece as
approved by the Engineer. Bolted or screwed on flanges are not acceptable.
The coating to the thrust/anchor flange shall be similar to that of the pipe/fitting.

19.2.3 Protective Coatings

A. Pipes shall be protected internally with factory applied cement mortar, fusion
bonded epoxy or polyurethane. Thickness of the cement mortar shall comply
with BS EN 545 requirements. The minimum dry film thickness of the fusion
bonded epoxy coating shall be 300 μm. Thickness of the polyurethane
application is given in the Table 19.2-1

B. Selection of the internal coating shall be made based on TSE properties and
manufacturer recommendations. Internal coatings shall comply with BS 6920

PAGE 102
DIVISION 02-SECTION 02640 FIRST EDITION -DECEMBER 2016
IRRIGATION SYSTEMS - TECHNICAL SPECIFICATIONS VOLUME III

requirements.

Table 19.2-1: Thickness of Internal Polyurethane Application

DN Nominal thickness of polyurethane (μm

100 - 600 1500
700-1000 1800
1100-1500 2200
1600-2000 2500
C. Pipes shall be protected externally with metallic zinc coat (min 200g/m2) and
epoxy finish layer (min thickness 80μM, metallic zinc coat (min 200g/m2) and
bituminous paint (min thickness 100μM or polyurethane. Selection of the
external coating shall be made on the base of soil conditions, refer to Table
19.2-2.
Table 19.2-2: External Coating of the Pipes Depending on the Soil Conditions

Soil characteristics External Coating

Resistivity >1500Ohmcm without water Metallic zinc + epoxy finish layer Metallic
table >2500Ohmcm with water table zinc + bituminous paint

750Ohmcm <Resistivity ≤ 1500 Ohmcm Metallic zinc + epoxy finish layer +

without water table polyethylene sleeve Metallic zinc +
1500Ohmcm<Resistivity ≤ 2500Ohmcm bituminous paint + polyethylene sleeve
with water table

Resistivity ≤750Ohmcm without water Polyurethane with average thickness

table ≤1500Ohmcm with water table 1000 μm

Resistivity ≤250Ohmcm without water Polyurethane with average thickness

table ≤500Ohmcm with water table 2000 μm

D. Fittings shall be protected internally and externally with a factory applied fusion
bonded powder epoxy resin coating. The minimum dry film thickness of the
coating shall be 300μm.

E. Epoxy coatings shall comply with EN 14901 requirements.

F. Polyurethane coatings shall comply with EN 15655 requirements.

G. Pipework and fittings shall be blast cleaned to SA2½ and grease and other
foreign matter shall be removed prior to application of the coating.

H. The coating shall be free from holidays, blisters, pinholes, runs, sags or any
other irregularities and shall have uniform color, gloss and thickness.

I. Method of site application of the internal and external coatings at the cut-off or
repaired pipes has to be produced by the pipe supplier and approved by the
Engineer

J. Polyethylene sleeve, when, used shall be in accordance with ISO 8180. The PE

PAGE 103
DIVISION 02-SECTION 02640 FIRST EDITION -DECEMBER 2016
IRRIGATION SYSTEMS - TECHNICAL SPECIFICATIONS VOLUME III

sleeve shall be black, UV resistant with the thickness 250 μm with maximum
minus tolerance of 10%
K. Dismantling joints, step couplings and flange adapters shall of be of steel grade
S275 to BS EN 10025 or ductile iron grade 420/12 to BS EN 1563 with factory
applied fusion bonded epoxy coating or Rilsan Nylon coating of minimum
thickness of 300 μm. Bolts, nuts, studs, and washers shall be stainless steel
SS316.

19.2.4 Marking of Pipes and Fittings

A. Marking shall be applied to pipes and fittings in such a manner that it is legible
after installation and durable throughout the construction period. Each pipe and
fitting shall be marked before dispatch from the pipe manufacturer’s works as
specified in BS EN 545 or ISO 2531.

19.3.Part3 Execution
19.3.1 Installation
A. Install in accordance with manufacturer’s recommendations and instructions.

B. Verify dimensions of valves and fittings to assure work will fit together properly
and conform to the arrangement shown on the drawings.

C. Accurately determine dimensions essential for proper location and orientation

of cast in items.

19.3.2 Jointing Pipes and Fittings

A. Thoroughly clean the faces of the flanges of all oil, grease, and foreign material
prior to connecting flanged pipe.
B. Check gaskets for proper fit and thoroughly clean.
C. Assure proper seating of the flange gasket.
D. Tighten bolts so that the pressure on the gasket is uniform. Use torque-limiting
wrenches to ensure uniform bearing insofar as possible.
E. If bolted joints leak when the hydrostatic test is applied, remove gaskets and
reset and retighten bolts.

19.3.3 Testing
A. Testing of the pipes and fittings shall be in accordance with BS EN 545
requirements.
B. All sections of DI pipeline and fittings shall be hydrostatically tested to the
satisfaction of the Engineer. The test pressure shall be such that the section
being tested will be subjected to 1.5 times the working pressure. The working
pressure shall be the maximum pressure that can be developed in the system.
C. All coatings and linings shall be tested in accordance to BS EN 545, EN 14901
and EN 15655 requirements. Where holidays are detected or the DFT is less
than required, the area shall be recoated in accordance with the
manufacturer’s recommendations.
END OF SECTION

PAGE 104
DIVISION 02-SECTION 02640 FIRST EDITION -DECEMBER 2016