QCS 2014 Section 08: Drainage Works Page 14

Part 03: Pipes and Fittings Materials

(ii) if a single end crack that does not exceed the depth of the joint exists in more
than 10 % of the pipes inspected, the defective pipes shall be rejected
(d) defects that indicate defective mixing and moulding
(e) surface defects indicating honeycomb or open texture

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(f) spalls

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(i) deeper than one half the depth of the joint
(ii) extending more than 100 mm around the circumference

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(iii) smaller than one half the depth of the joint or less than 100 mm around the

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circumference exist in more than ten percent of the pipes
(g) insufficient cover to the reinforcement.

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3.4 GLASS REINFORCED PLASTIC (GRP) PIPES AND FITTINGS

in
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3.4.1 Standards

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1 All activities relating to this section of the particular specification shall comply with the
following or approved equal standard. The latest version of the standard indicated shall
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apply.
Statutory provisions shall always apply as amended from time to time.
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Generally applicable standards:

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BS EN 681 .................Elastomeric seals. Material requirements for pipe joint seals used in
water and drainage applications.
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BS EN 14364 .............Plastic piping systems for drainage and sewerage with or without
pressure. Glass reinforced-thermosetting plastics (GRP) based on
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unsaturated polyester resin (UP). Specification for pipes, fittings and

joints
BS EN 1796................Plastic piping systems for water supply with or without pressure –
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Glass-reinforced thermosetting plastics (GRP) based on unsaturated

polyester resin (UP)
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CEN TS 14632 ...........Plastics piping systems for drainage, sewerage and water supply,
pressure and non-pressure - Glass-reinforced thermosetting plastics
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(GRP) based on unsaturated polyester resin (UP) - Guidance for the

assessment of conformity
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ISO 25780 ..................Plastic piping systems for pressure and non-pressure water supply,
irrigation, drainage or sewerage – Glass-reinforced thermosetting
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plastics (GRP) systems based on unsaturated polyester (UP) resin –

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Pipes with flexible joints intended to be installed using jacking

techniques
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ISO 3126 ...................Plastic pipes. Measurement of dimensions wall thickness table.

ISO 4633 ...................Joint rings for water supply, drainage and sewerage pipelines:
Specification for materials
ISO 1172 ....................Textile-glass-reinforced plastics, prepregs, moulding compounds and
laminates - Determination of the textile-glass and mineral-filler content
- Calcination methods
DIN 16 869 - Part 1 ...Centrifugally cast and filled glass fibre reinforced polyester resin pipes
- dimensions.
 QCS 2014 Section 08: Drainage Works Page 15
Part 03: Pipes and Fittings Materials

DIN 16 869 - Part 2 ...Glass-fibre reinforced polyester resin pipes (UP-GF) – Centrifugally
cast – filled Part 2: General quality requirements, testing.
DIN EN ISO 178 ........Plastics – Determination of flexural properties (ISO 178:1993)
DIN EN ISO 527-1 .....Plastics – Determination of tensile properties – Part 1: General
principles

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DIN EN ISO 527-2 .....Plastics - Determination of tensile properties - Part 2: Test conditions
for moulding and extrusion plastics

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ISO 15306 ..................Glass-reinforced thermosetting plastics (GRP) pipes — Determination
of the resistance to cyclic internal pressure

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ISO 10952 .................Plastics piping systems — Glass-reinforced thermosetting plastics

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(GRP) pipes and fittings — Determination of the resistance to
chemical attack for the inside of a section in a deflected condition
ISO 10928 ..................Plastics piping systems - Glass-reinforced thermosetting plastics

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(GRP) pipes and fittings - Methods for regression analysis and their

in
use

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DIN 16966 -6 ..............Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joint
assemblies; collars, flanges, joint rings, dimensions

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DIN-16945 .................Testing of Resins, Hardeners and Accelerators, and Catalyzed Resins
DIN-16946 - Part 1 ....Cured casting Resins - Testing DIN-16946- Part 2 Cured casting
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Resins - Types
DIN EN ISO 75 ..........Plastics – Determination of temperature of deflection under load
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DIN EN ISO 527-4 .....Plastics – Determination of tensile properties – Part 4: Test conditions
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for isotropic and orthotropic fibre-reinforced plastic composites

DIN EN ISO 10468 ....Glass-reinforced thermosetting plastics (GRP) pipes – Determination
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of the long-term specific ring creep stiffness under wet conditions and
calculation of the wet creep factor (ISO/DIS 10468:1999)
DIN EN ISO 14828 ....Glass-reinforced thermosetting plastics (GRP) pipes – Determination
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of the long-term specific ring relaxation stiffness under wet conditions

and calculation of the wet relaxation factor (ISO/DIS 14828:1999)
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DIN EN 681-1 ............Elastomeric seals – Material requirements for pipe joint seals used in
water and drainage applications – Part 1: Vulcanized rubber
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DIN EN 1119 .............Plastics piping systems – Joints for glass-reinforced thermosetting

plastics (GRP) pipes and fittings – Test methods for leak tightness and
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resistance to damage of flexible and reduced articulation joints

ISO 10466 .................Plastics piping systems — Glass-reinforced thermosetting plastics
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(GRP) pipes — Test method to prove the resistance to initial ring

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deflection
ISO 7685 .................... Plastics piping systems — Glass-reinforced thermosetting plastics
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(GRP) pipes — Determination of initial specific ring stiffness

ISO 8513 ....................Plastics piping systems — Glass-reinforced thermosetting plastics
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(GRP) pipes — Determination of longitudinal tensile properties

ISO 8521 ....................Plastic piping systems — Glass-reinforced thermosetting plastics
(GRP) pipes — Test methods for the determination of the apparent
initial circumferential tensile strength
DIN EN 1447 .............Plastics piping systems – Glass-reinforced thermosetting plastics
(GRP) pipes – Determination of long-term resistance to internal
pressure
 QCS 2014 Section 08: Drainage Works Page 16
Part 03: Pipes and Fittings Materials

ISO 7509 ....................Plastics piping systems — Glass-reinforced thermosetting plastics

(GRP) pipes —Determination of time to failure under sustained
internal pressure
ASTM D2997 .............Standard Specification for Centrifugally cast “Fiberglass” (Glass-Fiber-
Reinforced Thermosetting-Resin) Pipe.
EN ISO 2078 ..............Textile glass — Yarns — Designation (ISO 2078)

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ASTM D 3517-01 .......Standard Specification for “Fiberglass“(Glass-Fiber-Reinforced

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Thermosetting-Resin) Pressure Pipe

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3.4.2 Design

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1 The design of GRP pipes, fittings and bedding shall be carried out by the pipe manufacturer
to enable the pipe to meet the requirements of the Works. The following general
requirements shall prevail for pipes and fittings:

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(a) they shall be designed to achieve a minimum working life of 60 years under all

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applicable standard loadings, environmental and installation conditions

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2
(b) they shall have a minimum stiffness of 10,000 N/m

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(c) Non-pressure pipes and fittings shall be designed for a nominal pressure rating of PN
01 (1 bar)
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(d) Pressure pipes and fittings shall be designed for a normal operating pressure rating of
PN16 (16 bar) to pressure ratings in ISO 25780, EN 14364 or EN 1796.
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(e) they shall convey a liquid with a temperature up to 45C

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(f) they shall be designed to withstand up to 5% long term deflection in their installed
conditions.
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(g) all bends shall be long radius bends unless otherwise approved by the Engineer.
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(h) they shall be capable of withstanding a 95% lower confidence strain of 0.85% over 60
years without failure or cracking when tested in accordance with the strain corrosion
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type test requirements specified herein.

(i) sewerage and drainage pipelines and fittings shall be designed to carry septic sewage
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having a maximum hydrogen sulphide concentration of 50mg/l at a temperature of

45C
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(j) irrigation pipelines and fittings shall conform to the water supply standards
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(k) The manufacturer shall provide a valid Certificate of Conformity to EN 1796, EN 14364
or ISO 25780 as applicable. The certificate shall be issued by an independent
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certification body or authority.

(l) For direct jack GRP pipes, the allowable jacking force shall be based on the minimum
m

wall thickness measured at the bottom of the spigot gasket groove where the wall
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cross section has been reduced, and the mean longitudinal compressive strength of
the pipe. A minimum factor of safety of 3.5 in accordance with ISO 25780 shall be
used for the jacking force on a straight alignment. A reduced jacking force shall be
used when jacking to a curvature.
(m) Direct jack GRP pipes can be used for pressure and non-pressure applications.
 QCS 2014 Section 08: Drainage Works Page 17
Part 03: Pipes and Fittings Materials

3.4.3 Pipes and Fittings Manufacture

1 The pipes and fitting shall conform to either EN 14364 or EN 1796 for sewage or water
supply pipes. Jacking pipes shall comply with ISO 25780. The referenced test standards
therein have to be fulfilled.

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3.4.4 General

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1 All GRP components shall be designed and fabricated by one manufacturer.

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2 GRP pipes and fittings shall be manufactured by an approved process utilising a mandrel or
rotating mould incorporating equipment to accurately control the quantities and placement of

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all resins, glass and aggregates.

3 Use resins, reinforcement and aggregates to produce pipes and fittings, which when

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combined as a composite structure will satisfy the performance requirements of this section

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of the specification.

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4 Internal and external surfaces shall be free from irregularities, which would impair the ability

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of the component to conform to the requirements of EN 14364, EN 1796 or ISO 25780.
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3.4.5 Buried GRP

1 The pipes and fittings shall be constructed using chopped and /or continuous glass filaments,
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strands or roving, mats, synthetic veils or fabric, and polyester / vinyl ester resin, aggregate
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and fillers. If applicable, additives necessary to impart specific properties to the resin may be
used, subject to the approval of the Engineer.
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2 Filament Wound (FW) GRP Pipes and Fittings

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(a) Resins
Vinyl ester shall be used in the internal resin rich liner of the pipes and fittings.
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Isophthalic or vinyl ester shall be used in the structural layer of the pipes and fittings.
Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes and fittings.
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Resins shall be cured to achieve a minimum of 90% of the manufacturer’s

recommended Barcol hardness value.
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(b) Additives
The use of additives such as fire retardants, UV inhibitors or coloured pigments or
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dyes shall only be used for specific project based applications and their use shall be
subject to the approval of the Engineer.
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(c) Glass reinforcement

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The glass used for the manufacture of the reinforcement shall be type “E” (alumina-
calcosilicate glass), type “C” (alkali-calcium glass) or type “ECR” (alumina-borosilicate
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glass).
The reinforcement shall be made from continuous drawn filaments of glass and shall
have a surface treatment compatible with the resin to be used. It may be used in any
form, e.g. as continuous or chopped filaments, strands or rovings, mat or fabric.
(d) Aggregates
Aggregates shall be clean, graded silica sand containing no impurities and a maximum
moisture content of 2%. The maximum particles size of the sand aggregate shall not
exceed 0.8mm.
 QCS 2014 Section 08: Drainage Works Page 18
Part 03: Pipes and Fittings Materials

The overall sand content of the pressure pipes and fittings shall not exceed 30% by
weight.
The overall sand content of the non-pressure pipes and fittings shall not exceed 60%
by weight.
(e) Fillers

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Fillers (other than silica sand aggregate) shall only be permitted if required for a
particular project application and be subject to the approval of the Engineer following

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satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000
hours.

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(f) Wall construction

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Lining Layer
(i) The inner lining layer shall comprise a minimum 2.0mm thick rich vinyl ester
layer suitably reinforced with C glass veil with a glass content not exceeding

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10% by weight. The remainder of the lining shall consist of layers of vinyl ester

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resin and powder bound ECR acid resistant glass chopped strand mat or roving,

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depending on the method of manufacture, with a glass content of between 25%
and 35% by weight.

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(ii) Sand aggregate shall not be used in the lining layer.
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Structural Layer
(iii) The structural layer shall comprise Type E or ECR glass reinforcement and a
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thermosetting isophthalic polyester resin with or without sand aggregate.

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(iv) The layer shall be built up in layers of Type E or ECR acid resistant glass chop
roving or continuous roving.
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(v) The manufacturing process shall ensure that no aggregate becomes embedded
in the internal resin rich liner layer.
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Outer Layer
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(vi) Pipes shall be provided with a resin rich layer with C glass veil reinforcement.
(vii) The resin used in the outer layer shall have a Glass Transition temperature of at
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least 75C.
(viii) The use of special finishes is permitted when the pipe or fitting is expected to be
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exposed to extreme climatic, environmental or ground conditions. These may

include the provision of a sand layer, pigments or inhibitors for UV protection or
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fire retardation, subject to the approval of the Engineer.

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(g) Bends and Fittings

Bends and fittings shall be equal or superior in quality and performance to the
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corresponding pipes. Mitred bends and fittings shall be fabricated from pipes which
have been hydraulically tested successfully.
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3 Centrifugally Cast (CC) GRP Pipes and Fittings

(a) Resins
Vinyl ester shall be used in the internal pure resin liner of the pipes and fittings.
Isophthalic or vinyl ester shall be used in the structural layer of the pipes and fittings.
Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes and fittings.
Resins shall be cured to achieve a minimum of 90% of the manufacturer’s
recommended Barcol hardness value.
 QCS 2014 Section 08: Drainage Works Page 19
Part 03: Pipes and Fittings Materials

(b) Additives
The use of additives such as fire retardants, UV inhibitors or coloured pigments or
dyes shall only be used for specific project based applications and their use shall be
subject to the approval of the Engineer.
(c) Glass reinforcement

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The glass used for the manufacture of the reinforcement shall be Type E or ECR
glass.

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The reinforcement shall be made from chopped glass filament in long and short fibres
and shall have a surface treatment compatible with the resin to be used.

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(d) Aggregates

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Aggregates shall be clean, graded silica sand containing no impurities and a maximum
moisture content of 2%. The maximum particles size of the sand aggregate shall not
exceed the lesser of 1/5 the total wall thickness of the pipe or fitting, or 2.5mm.

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(e) Fillers

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Fillers (other than silica sand aggregate) shall only be permitted if required for a

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particular project application and be subject to the approval of the Engineer following

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satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000
hours.
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(f) Wall construction
Lining Layer
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(i) The inner lining layer shall comprise a minimum 2.0mm thick pure vinyl ester
resin without glass reinforcement and sand aggregates.
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(ii) The barrier and transition layers between the pure resin lining layer and the
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structural layer shall be to suit the manufacturing process.

Structural Layer
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(iii) The structural layer shall comprise glass reinforcement and a thermosetting
isophthalic polyester or vinyl ester resin with or without sand aggregate.
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(iv) The layer shall be built up in layers of ECR acid resistant glass chopped fibres.
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(v) The manufacturing process shall ensure that no aggregate becomes embedded
in the inner pure resin liner layer.
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Outer Layer
(vi) Pipes shall be provided with an outer layer formed of a mortar of resin and sand
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aggregates with no glass reinforcement.

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(vii) The resin used in the outer layer shall have a Glass Transition temperature of at
least 75C.
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(viii) An outer protection layer shall be provided which has a minimum of 60% sand
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for corrosion protection.

(ix) The use of special finishes is permitted when the pipe or fitting is expected to be
exposed to extreme climatic, environmental or ground conditions. These may
include the provision of a sand layer, pigments or inhibitors for UV protection or
fire retardation, subject to the approval of the Engineer.
(x) The transition layers between the structural layer and the outer layer shall be to
suit the manufacturing process.
 QCS 2014 Section 08: Drainage Works Page 20
Part 03: Pipes and Fittings Materials

(g) Bends and Fittings

Bends and fittings shall be equal or superior in quality and performance to the
corresponding pipes. Mitred bends and fittings shall be fabricated from pipes which
have been successfully pressure tested.

4 Direct Jack GRP Pipes

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(a) Resins

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Vinyl ester resin shall be used in the internal pure resin liner of the pipes. Isophthalic
or vinyl ester resin shall be used in the structural layer of the pipes. Vinyl ester or

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isophthalic resin shall be used in the outer layer of the pipes.

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Resins shall be cured to achieve a minimum of 90% of the manufacturer’s
recommended Barcol hardness value.
(b) Additives

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The use of additives such as fire retardants, UV inhibitors or coloured pigments or
dyes shall only be used for specific project based applications and their use shall be

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subject to the approval of the Engineer.

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(c) Glass reinforcement
The glass used for the manufacture of the reinforcement shall be Type E or ECR acid
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resistant glass.
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The reinforcement shall be made from chopped glass filament in long and short fibres
and /or continuous glass filaments, strands or roving, mats, synthetic veils or fabric
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and shall have a surface treatment compatible with the resin to be used.
(d) Aggregates
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Aggregates shall be clean, graded silica sand containing no impurities and a maximum
moisture content of 2%. The maximum particles size of the sand aggregate shall not
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exceed the lesser of 1/5 the total wall thickness of the pipe or fitting, or 2.5mm.
ab

(e) Fillers
Fillers (other than silica sand aggregate) shall only be permitted if required for a
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particular project application and be subject to the approval of the Engineer following
satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000
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hours.
(f) Wall construction
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Lining Layer
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(i) The inner lining layer shall comprise a minimum 2.0mm thick rich vinyl ester
layer suitably reinforced with C glass veil with a glass content not exceeding
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10% by weight. The remainder of the lining shall consist of layers of vinyl ester
resin and powder bound ECR acid resistant glass chopped strand mat or roving,
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depending on the method of manufacture, with a glass content of between 25%

and 35% by weight, when the filament wound manufacturing process is used.
(ii) The inner lining layer shall comprise a minimum 2.0mm thick pure vinyl ester
resin without glass reinforcement and sand aggregates when the centrifugal
manufacturing process is used.
(iii) The barrier and transition layers between the pure resin lining layer and the
structural layer shall be to suit the manufacturing process.
 QCS 2014 Section 08: Drainage Works Page 21
Part 03: Pipes and Fittings Materials

Structural Layer
(iv) The structural layer shall comprise glass reinforcement and a thermosetting
isophthalic polyester or vinyl ester resin with or without sand aggregate.
(v) The layer shall be built up in layers of Type E or ECR acid resistant glass
chopped fibres.

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(vi) The manufacturing process shall ensure that no aggregate becomes embedded

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in the inner pure resin liner layer.
Outer Layer

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(vii) Pipes shall be provided with an outer layer formed of a mortar of resin and sand

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aggregates with no glass reinforcement.
(viii) The resin used in the outer layer shall have a Glass Transition temperature of at
least 75C.

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(ix) An outer protection layer shall be provided which has a minimum of 60% of sand
for corrosion protection.

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(x) The use of special finishes is permitted when the pipe is expected to be

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exposed to extreme climatic, environmental or ground conditions. These may
include the provision of a sand layer, pigments or inhibitors for UV protection or
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fire retardation, subject to the approval of the Engineer.
(xi) The transition layers between the structural layer and the outer layer shall be to
C

suit the manufacturing process.

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(xii) The outer surface of the pipes shall be smooth with a resin rich topcoat 0.3mm
thick.
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(g) Longitudinal Compressive Strength

Proof of compression strength shall be supplied by testing all pipe types using the
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procedure set out in Annex A of ISO 25780.

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The test results of compressive properties obtained from coupon or spool test
specimens may be used. As described in ISO 25780, the manufacturer shall show the
correlation of the results obtained from coupons or full spools by means of initial type
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tests. The pipes shall meet the following requirements for the initial longitudinal
compression properties:
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Table 3.4.1 : Longitudinal compressive strength for direct jack GRP pipes
Mean
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Minimum compressive
Specimen Pipe quality compressive
strength (single value)
strength
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Rebated and grooved with filler 80 MPa 90 MPa

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specimen

Coupon specimen with filler 90 MPa 100 MPa

Rebated and grooved without filler 70 MPa 80 MPa

specimen

Coupon specimen without filler 80 MPa 90 MPa

 QCS 2014 Section 08: Drainage Works Page 22
Part 03: Pipes and Fittings Materials

(h) Dimensions
The manufacturer shall confirm that the outside diameter of the pipe conforms to ISO
25780.
The outside diameter of the jacking pipe shall be compatible with the jacking machine.
The nominal length of the pipe shall preferably be 1m, 1.5m, 2m, 3m or 6m. Other

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lengths shall be permitted to suit a particular project requirement.

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The jacking force shall be transmitted face to face on the pipe joint without the use of
packer rings, unless required for a specific project application. The permitted deviation

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from squareness across the joints external diameter shall be as tabled below:

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Table 3.4.2 : Permissible deviation from squareness across a joint’s external diameter

Manufacturer’s declared outside Deviation of

diameter dOD mm squareness mm

g
in
dOD ≤ 300 0.5

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300 < dOD 1.0

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(i) Marking of jacking pipes
Markings shall meet the requirements for the application and conform to ISO 25780.
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Designations to meet special quality requirements as item 6 below are permissible.

The marking of the pipe shall be visible on the external and internal surfaces of the
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jacking pipe.
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5 Wall thickness
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The minimum total wall thickness, including the liner and outer protective layer shall be
declared by the manufacturer, which shall be complying with the standard performance
criteria.
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The wall thickness at any point on the pipe and the spigot shall not be less than the
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manufacturer’s declared values.

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6 Abrasion resistance
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The pipes shall be resistant to abrasion when tested according to CEN TR 15729 over
100,000 cycles. There shall be no evidence of free glass fibres on the inner surface of the
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pipe.
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7 Markings
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All pipes including cut lengths and all fittings before dispatch from the pipe manufacturer’s
works shall be indelibly marked as follows on the external and internal surfaces.

(a) The manufacturer's name, initials, or identification mark.

(b) The nominal internal diameter in millimetres.
(c) The length in metres.
(d) The classification i.e. pressure rating, stiffness.
 QCS 2014 Section 08: Drainage Works Page 23
Part 03: Pipes and Fittings Materials

(e) The date of manufacture and batch number.

(f) A stamp to show that they meet the required inspection requirements and hydraulic
tests at the point of manufacturer.
(g) Identification number stencilled on the inside and outside at each end. The same
number shall appear on all record sheets and documents relating to the manufacture

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delivery and testing of that pipe.

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(h) The manufacturing standard.
(i) The project or contract number.

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8 Joints

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Except where otherwise detailed on the Drawings, all buried pipes and fittings shall have non-
end-load-bearing flexible joints of spigot type or GRP sleeved couplers with EPDM rubber in

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full faced elements or rings in accordance with BS / DIN EN 681; manufactured according to

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the individual manufacturing technique and supplied as an integral part of the pipe or as
separate fittings. The elastomeric sealing gaskets shall provide the sole means of

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maintaining joint watertightness. The sealing gaskets shall be supplied by the pipe

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manufacturer. on
Joints in direct jack applications (non-pressure application) can also be of stainless steel
Grade 316 Ti (EN 1.4571) couplers with approximately the same outside diameter as the
pipe so that the joints are essentially flush with the pipe outer surface.
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The manufacturer shall declare the maximum draw for which each flexible joint type is
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designed.
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The manufacturer shall declare the maximum allowable angular deflection and the maximum
draw for which each locked joint type and flexible joint type are designed.
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All joints shall remain watertight for all combinations of angular deflection and draw up to the
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maximum allowable values. In addition, pipe joints for pipelines laid in open cut trenches
shall be capable of withstanding an external pressure differential equivalent to +10m head of
water without leakage in the straight, deflected and drawn positions.
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When a pipe is cut or turned down in order to form a joint, the exposed faces shall be fully
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sealed with a continuous coating of vinyl ester resin with a minimum of 1.5mm thick.
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Wrapped or cemented joints shall only be used subject to the approval of the Engineer.
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3.4.6 Exposed GRP

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The use of GRP pipes and fittings for exposed service shall be subject to the approval of the
Engineer. The exposed pipes and fittings shall be designed to resist all bending stresses,
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thrust forces, surge pressures, negative pressures, thermal and vibratory forces.

1 Exposed pipe and fittings shall be manufactured in the same manner and with the same
materials as buried pipe, along with the following requirements unless otherwise approved by
the Engineer.
 QCS 2014 Section 08: Drainage Works Page 24
Part 03: Pipes and Fittings Materials

(a) An outer protective surface layer shall be provided consisting of a topcoat of UV

inhibitor and resin with or without glass reinforcement to form a resin rich layer with a
minimum thickness of 0.3mm. The outer protective surface layer shall be designed to
resist other project specific extraneous causes (atmospheric conditions, mechanical
damage and chemical stress etc.) as described in the project specification.

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2 Exposed pipes and fittings inside treatment plant buildings, process structures, pumping
stations, and valve chambers shall use PN 16 flanged joints:

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(a) Flanges shall be filament wound, tape wound, contact moulded, hot or cold pressed

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with epoxy or vinyl ester resins only.

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(b) All bolts shall be stainless steel grade 316.
(c) Flanges shall be drilled to BS EN 1092 (metric units) resp. DIN 16966-1 type PN16.
(d) Flanged pipe joints shall incorporate an annular gasket covering the full face of the

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flange. Gaskets to be 3mm thick self-energised EPDM or nitrile rubber (NBR) with

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embedded stainless steel inlay O rings. The gaskets shall have a shore hardness of

ct
60±5.

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(e) When flanged joints are to be made, secure the bolts and the nuts initially to finger
tightness. Thereafter the final tightening of the nuts shall be effected by torque
spanners in such sequence that diametrically opposite nuts are tightened together to
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achieve the manufacturers recommended torque.
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3 External exposed pipes and fittings shall use fixed laminated joints with expansion bellows
and be supported in accordance with the manufacturer’s requirements.
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4 The exposed pipeline shall be protected by bollards, lateral sand bunds etc. where there is a
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risk of physical impact.

3.4.7 Inspection and Testing

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1 A pipe type test group consists of a range or family of products made such that the results of
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the long-term type tests are applicable to all products in the group. A pipe type test group
shall be made of products:
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a) manufactured by the same process;

b) with the same material specifications;
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c) with the same pipe wall construction (i.e. the sequence of layers, layer
compositions, material properties and design method for using the results of the
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long-term type tests in determining the pipe wall for all combinations of DN, PN
and SN);
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d) tested with the same loading condition (i.e. uniaxial or biaxial load).
2 The pipe manufacturer shall submit type test results according to EN 14364 or ISO 25780 for
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each product group.

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3 Strain corrosion tests shall be carried for each class and diameter range, where applicable,
according to ISO 25780 and ISO 10467, as a type test generally in accordance with ASTM
D3262 resp. ISO 10952. The strains shall be at levels at which failure can be predicted from
the strain corrosion type test results to occur at 100 hours and 1,000 hours. No failures shall
be below the lower 95% confidence limit of the type test regression line.
4 The calculated failure strain at 60 years from the results of the quality control test using the
least squares method shall not be less than 0.85%. In the event that a specimen fails the
strain corrosion test all pipes in that class and diameter range, where applicable, pertaining to
that batch which has been manufactured or installed shall be rejected.
 QCS 2014 Section 08: Drainage Works Page 25
Part 03: Pipes and Fittings Materials

5 The pipe manufacturer shall carry out the following Inspection Tests. The results of these
tests shall be made available to the Engineer who shall also be allowed to witness some or
all of the tests.
(a) One pipe in every 100 of each type and size of manufactured item shall be tested for
loss of ignition in accordance with ASTM D2584 resp. ISO 1172.
(b) The liner thickness of pipes, fittings and couplings shall be measured in accordance with

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Section 6 of ASTM D3567 resp EN 3126. A liner check shall be carried out for one in
every 100 of each type and size of manufactured item. A minimum of one item of each

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type and size shall be tested. The liner thickness shall not be less than 1mm at any
pitted point.

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(c) Data for the above tests shall be submitted to the Engineer. The data shall be traceable

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to the supplied pipes with a unique number as "Batch no", the test data shall hold all the
above mentioned tests samples results under this batch no. The batch no. shall be
clearly marked as ID on each length of produced pipes.

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6 Checks will be carried out by the Engineer at Site. The Contractor shall destroy or indelibly
mark as rejected and remove from Site any pipes or fittings found at any time failing to meet

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dimensional criteria or any of the following quality criteria:

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(a) scratches shall be no deeper than 0.3 mm and no reinforcing fibres shall be exposed

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(b) no cracks shall be present on the inside of pipes. Hair cracks on the outside may be
permitted with repair if not longer than 200 mm circumferentially or 6 mm longitudinally.
Impact cracks shall not affect more than 3 % of surface area
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(c) no delaminations shall be evident
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(d) no impact or other damage to pipe ends shall be evident. The end surface of pipe or
fitting shall be completely covered with resin and free from cracks, porosity, bubbles,
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voids, exposed reinforcement or extraneous matter

(e) no protruding fibres permitted on jointing surfaces
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(f) no other protuberances. Small globules or resin projections permissible if not more than
25 % of area is affected. Jointing surfaces shall be completely free of any such flaws.
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Ridges formed by resin shall not exceed 1.5 mm in depth

(g) air voids, blisters, bubbles are not acceptable if greater than 5 mm diameter or 1 mm
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depth. Subject to the approval of the Engineer, if less than 0.5% of internal areas are
affected, such defects may be ground out and repaired
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(h) not more than 5 % of the internal or 10 % of the external surface shall be affected by
pitting. No individual pit shall be more than 1 mm diameter or 0.5mm depth
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(i) wrinkles and indentations shall not be more than 2mm deep and not more than 3 % of
surface area affected. Subject to the approval of the Engineer, if not more than 5 mm
deep and 0.5 percent of surface area is affected, such defects may be repaired
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(j) any pipe which when resting freely on the ground and not subjected to any loads other
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than its own weight exhibits a deflection of more than 2%, measured along the diameter,
shall be rejected and removed from the Site.
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3.5 PVC-U PIPES AND FITTINGS

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1.1.1 Standards

1 Except as otherwise indicated, materials and workmanship described in this section shall
conform to the latest editions of the following standards:
ASTM D1599 ..............Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe,
Tubing and Fittings