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This document provides standards for general civil construction projects for Watercare. It outlines requirements for various civil construction activities including: site works, earthworks, pipe laying, concrete works, painting, demolition, masonry, plumbing, carpentry, metal roofing, polymer chambers, and testing. The document underwent minor revisions in version 1.1 including updates to referenced standards, requirements for tracer wire installation and HDD works, and clarification of tolerances for pipe laying. It is meant to be used in conjunction with Watercare's other cross-referenced standards and drawings.

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Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 1 of 92 General Civil Construction Standard No. CG Ver.1.1 Date: 19 June 2019
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 2 of 92 Revision Description Released By Date 0.1 First draft J de Villiers 8/10/2015 1 First release J de Villiers – Principal Engineer, Standards 14/10/2016 1.1 Updates to pipeline testing, location of pipe services and standard references. Document formatting changes J de Villiers 19/06/2019 Reviewers: Version 1.1: Simon Porter – Head of Service Delivery, Operations James Eardley - Projects Manager, Infrastructure Construction Graham Nairn – Asset specialist, Civil Operations Andrew Mercer – Site Engineering Manager Version 1: Martin Smith – General Manager Strategy and Planning, Watercare Geof Stewart – Manager Asset Strategy, Watercare Chris Allen – Wastewater Strategy Manager, Watercare James Eardley - Projects Manager, Watercare Brian Park – Discipline Engineer Water, Watercare
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 3 of 92 Summary of changes Version Section Description of revision 1.1 2.2 Selection deleted, serves no purpose to document content 4.1 Text updates to refer Watercare compliance policy 4.2 Text updates to refer commissioning code of practice 5 Section updated with Watercare cross-referenced standards and drawings to be used in conjunction with the construction standard. Minor update of referenced national standards. 6.1 Text revision to delete text duplicated in referenced standard 7; C2.1 Include reference to Watercare HSE standard requirements C2 Minor updates to section to include dewatering consent considerations and terminology corrections C3 Section references included to use manufacturer recommended pipe jointing. Minor wording corrections across section C3.1 Clarification added on expectations for pipe oval checking by pigging or scanning method – added to QA/QC C3.1.5; C3.1.6 Updated text to clarify horizontal and vertical clearances for pipe laying and the allowable tolerances. Note at end of section relocated to prevent misinterpretation. C3.1.7 New section to describe tracer wire installation requirements C3.2 Added discovery protocols for tunnelling works, in addition to HSE. Updated reporting C3.3 Section updated with information to be provided, record keeping and QA requirements for HDD C3.4.1 Clause expanded to clarify when pipe curving may be accepted for gravity or ducted services. C3.4.2 Removed duplication of bend manufacturing. Referred to material supply standard C3.10.1 Minor working changes to clarify use of CCTV before and after lining application C5.1; C5.2 Updated note. Corrected painting code C11 New section describing polymer-type chamber installations 10.5, Table A1 Expanded table to extend testing length 10.5.1 B-6) Section updated to clarify test result interpretation 10.5.1 B-9) New hydrostatic pressure test added for testing PE pipe All sections Added paragraph numbering to improve reference
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 4 of 92 Table of contents DEFINITIONS....................................................................................................................................................9 1. INTRODUCTION.....................................................................................................................................11 2. STANDARD DOCUMENTS OVERVIEW.....................................................................................................11 3. QUALITY CONTROL AND QUALITY ASSURANCE .....................................................................................12 4. GENERAL ENGINEERING DOCUMENT SUBMITTAL REQUIREMENTS .......................................................12 5. REFERENCED STANDARDS .....................................................................................................................13 6. MATERIALS............................................................................................................................................16 7. HEALTH AND SAFETY .............................................................................................................................16 8. ASSET CAPTURE.....................................................................................................................................16 9. CIVIL CONSTRUCTION............................................................................................................................17 C1. SITE ROADING ...................................................................................................................................17 C1.1 General ................................................................................................................................................17 C1.2 Paving subgrade preparation...............................................................................................................17 C1.3 Subsoil drains.......................................................................................................................................17 C1.4 Basecourse and sub-base.....................................................................................................................17 C1.5 Asphaltic concrete ...............................................................................................................................17 C1.6 Kerbing.................................................................................................................................................18 C1.7 Stormwater drainage...........................................................................................................................18 C1.8 QA/QC template ..................................................................................................................................18 C2. EARTHWORKS ...................................................................................................................................18 C2.1 General ................................................................................................................................................18 C2.2 Site preparation ...................................................................................................................................18 C2.3 Geotechnical investigations.................................................................................................................19 C2.4 Topsoil stripping...................................................................................................................................19 C2.5 Stockpiling............................................................................................................................................19 C2.6 Excavation support and perimeter protection ....................................................................................19 C2.7 Excavation general...............................................................................................................................19 C2.8 Water in excavations ...........................................................................................................................19 C2.9 Excavation for trenches .......................................................................................................................20 C2.10 Excavation for structures...................................................................................................................20 C2.11 Excavation by hydro-vacuum excavation...........................................................................................20 C2.12 Excavation by explosive blasting........................................................................................................20 C2.13 Excavation material classification......................................................................................................20 C2.14 Backfill and fill in general...................................................................................................................21 C2.15 General compaction of backfill..........................................................................................................21 C2.16 Backfill material classification............................................................................................................21 C2.17 Surface reinstatement .......................................................................................................................22 C2.18 Top soil and grass reinstatement.......................................................................................................22 C2.19 Surplus material.................................................................................................................................22 C2.20 Record keeping ..................................................................................................................................22 C2.21 QA/QC template ................................................................................................................................22 C3. PIPE AND DUCT LAYING .......................................................................................................................23 C3.1 General Pipeline construction .............................................................................................................23 C3.1.1 Position tolerances.........................................................................................................................................24 C3.1.2 Bedding material, pipe surround and compaction.........................................................................................24
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 5 of 92 C3.1.3 Pipe laying in embankment............................................................................................................................24 C3.1.4 Pipelines through structures ..........................................................................................................................25 C3.1.5 Parallel pipeline separation............................................................................................................................25 C3.1.6 Vertical separation from other services .........................................................................................................25 C3.1.7 Trace wire installation....................................................................................................................................25 C3.1.8 QA/QC template.............................................................................................................................................26 C3.2 Pipe jacking, boring or tunnelling and shaft sinking ............................................................................27 C3.2.1 General...........................................................................................................................................................27 C3.2.2 Jacking pits, headings and shafts....................................................................................................................29 C3.2.3 Installations under roads or other facilities....................................................................................................29 C3.2.4 Over excavation and grouting ........................................................................................................................29 C3.2.5 Pipe jacking ....................................................................................................................................................29 C3.2.6 Micro-tunnelling.............................................................................................................................................29 C3.2.7 Reinstatement of jacking pits.........................................................................................................................29 C3.2.8 Record keeping...............................................................................................................................................30 C3.2.9 QA/QC template.............................................................................................................................................30 C3.3 Horizontal directional drilling (HDD)....................................................................................................30 C3.3.1 Calculations ....................................................................................................................................................31 C3.3.2 Construction plan...........................................................................................................................................31 C3.3.3 Tracking systems ............................................................................................................................................32 C3.3.4 Drilling fluids and cuttings management plan................................................................................................32 C3.3.5 Contingency plans ..........................................................................................................................................32 C3.3.6 Grouting .........................................................................................................................................................32 C3.3.7 Record keeping...............................................................................................................................................32 C3.3.8 QA/QC template.............................................................................................................................................33 C3.4 Installation of polyethylene pipe .........................................................................................................34 C3.4.1 Pipe curving....................................................................................................................................................34 C3.4.2 Pipe bends and fittings...................................................................................................................................35 C3.4.3 Pipe jointing ...................................................................................................................................................35 C3.4.4 Equipment......................................................................................................................................................36 C3.4.4 QA/QC templates ...........................................................................................................................................38 C3.5 Repair of polyethylene pipe.................................................................................................................40 C3.6 Installation of welded steel pipelines ..................................................................................................40 C3.6.1 Pipe bends and other assemblies...................................................................................................................40 C3.6.2 Pipe joints.......................................................................................................................................................40 C3.6.3 Corrosion protection......................................................................................................................................41 C3.6.4 Concrete lined steel pipe - Wastewater specific requirements......................................................................42 C3.6.5 QA/QC templates ...........................................................................................................................................42 C3.7 Installation of PVC pipelines ................................................................................................................42 C3.7.1 Pipe Joints ......................................................................................................................................................42 C3.7.2 QA/QC template.............................................................................................................................................43 C3.8 Installation of Ductile Iron (DI) pipe.....................................................................................................43 C3.8.1 Pipe Joints ......................................................................................................................................................43 C3.8.4 Pipe deflection with spigot joints...................................................................................................................43 C3.7.2 QA/QC template.............................................................................................................................................44 C3.9 Concrete and Ceramic pipes (Wastewater only) .................................................................................45 C3.9.1 General...........................................................................................................................................................45 C3.9.2 Cutting of pipes ..............................................................................................................................................45 C3.9.3 Pipe Laying .....................................................................................................................................................45 C3.9.4 Laying on a curve............................................................................................................................................45 C3.9.5 Rubber ring joints...........................................................................................................................................45 C3.9.6 Mechanical joints ...........................................................................................................................................45 C3.9.7 Repair .............................................................................................................................................................45 C3.9.8 QA/QC Template ............................................................................................................................................46 C3.10 Pipe structural lining..........................................................................................................................46 C3.10.1 General.........................................................................................................................................................46
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 6 of 92 C3.10.2 Access...........................................................................................................................................................46 C3.10.3 Pipeline cleaning ..........................................................................................................................................46 C3.10.4 CCTV requirements ......................................................................................................................................46 C3.10.5 Pipe repairs ..................................................................................................................................................47 C3.10.6 Polymer lining methods ...............................................................................................................................47 C3.10.7 Cement and mortar in-situ lining methods ..................................................................................................47 C3.10.8 Record keeping.............................................................................................................................................47 C3.10.9 QA/QC Template ..........................................................................................................................................48 C3.11 Pipelines brought into service ...........................................................................................................48 C4. CONCRETE........................................................................................................................................49 C4.1 Construction of reinforced concrete structures ..................................................................................49 C4.1.1 Reinforcement................................................................................................................................................49 C4.1.2 Construction joints .........................................................................................................................................50 C4.1.3 Contraction joints...........................................................................................................................................50 C4.1.4 Slump tolerance .............................................................................................................................................51 C4.1.5 Vibration.........................................................................................................................................................51 C4.1.6 Surface finish..................................................................................................................................................51 C4.1.7 Penetrations through structures....................................................................................................................51 C4.1.8 Records...........................................................................................................................................................51 C4.1.9 QA/QC template.............................................................................................................................................52 C4.2 Construction of enclosed chambers, manholes and small structures .................................................52 C4.2.1 General...........................................................................................................................................................52 C4.2.1 Foundation .....................................................................................................................................................53 C4.2.2 Roof slab, lids and access ...............................................................................................................................53 C4.2.3 Infiltration performance.................................................................................................................................53 C4.2.4 QA/QC template.............................................................................................................................................53 C4.4 Shotcreting...........................................................................................................................................53 C4.4.1 General...........................................................................................................................................................53 C4.4.2 Preparation and trial ......................................................................................................................................53 C4.4.3 Placement of shotcrete ..................................................................................................................................54 C4.4.4 Finishing .........................................................................................................................................................54 C4.4 5 Joints ..............................................................................................................................................................54 C4.4.6 QA/QC template.............................................................................................................................................54 C4.5 Formwork.............................................................................................................................................55 C4.6 Concrete defect repairs .......................................................................................................................55 C4.6.1 Patch repairs ..................................................................................................................................................55 C4.6.2 Crack repairs...................................................................................................................................................55 C4.6.3 QA/QC template.............................................................................................................................................55 C4.7 Rehabilitation of wastewater pipe and structures with cement mortar.............................................56 C4.7.1 General...........................................................................................................................................................56 C4.7.2 Surface preparation........................................................................................................................................56 C4.7.3 Mortar application .........................................................................................................................................56 C4.7.4 Record keeping...............................................................................................................................................56 C4.7.5 QA/QC Template ............................................................................................................................................56 C5. PAINTING.........................................................................................................................................57 C5.1 General ................................................................................................................................................57 C5.2 Painting of pipes, equipment and structures.......................................................................................57 C5.2.1 External pipe painting ....................................................................................................................................58 C5.2.2 Internal pipe painting.....................................................................................................................................58 C5.2.3 Painting of buildings.......................................................................................................................................58 C5.3 Field touch-up painting........................................................................................................................62 C5.4 Protection of work and adjacent equipment.......................................................................................62 C5.5 Valve box cover paint colours..............................................................................................................62 C5.6 Painting equipment .............................................................................................................................62 C5.7 QA/QC template ..................................................................................................................................63
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 7 of 92 C6. DEMOLITION AND ABANDONMENT ........................................................................................................64 C6.1 General ................................................................................................................................................64 C6.2 Existing work and damage ...................................................................................................................64 C6.3 Protection of people, property and environment ...............................................................................64 C6.4 Removal of material.............................................................................................................................64 C6.5 QA/QC template ..................................................................................................................................64 C7. MASONRY........................................................................................................................................64 C7.1 Workmanship.......................................................................................................................................64 C7.2 Materials handling and block types.....................................................................................................65 C7.3 Laying of masonry................................................................................................................................65 C7.4 Clean-out ports ....................................................................................................................................65 C7.5 Control joints .......................................................................................................................................65 C7.6 Reinforcement .....................................................................................................................................66 C7.7 Filling cores ..........................................................................................................................................66 C7.8 QA/QC template ..................................................................................................................................66 C8. PLUMBING .......................................................................................................................................66 C8.1 General ................................................................................................................................................66 C8.2 QA/QC template ..................................................................................................................................67 C9. CARPENTRY ......................................................................................................................................67 C9.1 Workmanship.......................................................................................................................................67 C9.2 Fasteners and fixings............................................................................................................................67 C9.3 Timber treatment ................................................................................................................................67 C9.4 Timber sizes .........................................................................................................................................68 C9.5 Framing................................................................................................................................................68 C9.6 Moisture content.................................................................................................................................68 C9.7 Material handling.................................................................................................................................68 C9.8 QA/QC template ..................................................................................................................................68 C10. METAL ROOFING................................................................................................................................68 C10.1 General ..............................................................................................................................................68 C10.2 Execution of work ..............................................................................................................................69 C10.3 Joints..................................................................................................................................................69 C10.4 Capping, flashings and other hardware.............................................................................................69 C10.5 Damage and performance .................................................................................................................69 C10.5 QA/QC template ................................................................................................................................69 C11. POLYMER-TYPE CHAMBERS ..................................................................................................................70 C11.1 Approved chambers...........................................................................................................................70 C11.2 Foundation.........................................................................................................................................70 C11.3 Penetrations.......................................................................................................................................70 C11.4 Infiltration performance ....................................................................................................................70 C11.5 Backfill................................................................................................................................................70 C11.6 QA/QC template ................................................................................................................................70 10. TESTING ............................................................................................................................................71 10.1 ROADING AND DEVELOPMENT....................................................................................................................71 10.2 BACKFILL COMPACTION TESTING.................................................................................................................71 10.3 INSTALLATION OF POLYETHYLENE PIPE..........................................................................................................71 10.4 STEEL PIPE WELD BAND, SOCKET AND SPIGOT JOINTS – PIPE ≥700MM NB ...........................................................72 10.5 PRESSURE AND LEAKAGE TESTING ...............................................................................................................72 10.5.1 Pipeline testing .................................................................................................................................72 A) Non-pressure pipelines – Field leakage testing ...............................................................................................72 A-1) Low pressure air test .........................................................................................................................................73
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 8 of 92 A-2) Hydrostatic test .................................................................................................................................................74 B) Pressure pipelines general requirements – Field hydrostatic pressure testing...............................................74 B-1) Selection of test pressure ..................................................................................................................................75 B-2) Selecting test lengths.........................................................................................................................................75 B-3) Pre-test procedures ...........................................................................................................................................75 B-4) Post-test procedures..........................................................................................................................................76 B-5) Constant pressure test (water loss method) – PVC, DI, GRP, and steel pipelines..............................................78 B-6) Pressure decay test for PE pipe larger than DN200 or longer than 250m .........................................................78 B-7) Pressure rebound test for PE up to DN 200.......................................................................................................80 B-8) Visual test for small pressure pipelines .............................................................................................................80 B-9) Hydrostatic pressure test for PE pressure pipelines ..........................................................................................81 10.5.2 Manhole and chamber (concrete) testing ........................................................................................81 A) Hydrostatic testing of concrete manholes.......................................................................................................81 B) Vacuum test.....................................................................................................................................................82 C) Infiltration test.................................................................................................................................................82 D) Visual check (smoke test) ................................................................................................................................83 10.5.3 Manhole (plastic/GRP material) testing............................................................................................83 10.5.4 Fluid retaining structures (process tanks, reservoirs, etc.)...............................................................83 A) Concrete tanks.................................................................................................................................................83 B) PE, GRP, steel tanks .........................................................................................................................................85 10.6 POTABLE WATER INFRASTRUCTURE DISINFECTION...........................................................................................85 10.7 CONCRETE – BUILDINGS AND STRUCTURES ....................................................................................................85 10.8 SHOTCRETE............................................................................................................................................85 10.9 MASONRY.............................................................................................................................................85 10.10 TESTING OF PLUMBING INSTALLATIONS ......................................................................................................85 10.11 TIMBER MOISTURE CONTENT ...................................................................................................................86 10.12 DIRECT CURRENT VOLTAGE GRADIENT (DCVG) COATING DEFECT SURVEY FOR NEW STEEL PIPELINES .........................86 10.12.1 DCVG survey types..........................................................................................................................86 10.12.2 Minimum qualifications..................................................................................................................86 10.12.3 Testing.............................................................................................................................................86 10.12.3.1 Visual inspection & preliminary tests........................................................................................................86 10.12.3.2 Method......................................................................................................................................................86 10.12.4 DCVG survey procedures ................................................................................................................89 10.12.5 Acceptance criteria .........................................................................................................................90 10.12.6 Re-test following defect correction ................................................................................................90 10.12.7 Report .............................................................................................................................................92 10.13 MORTAR REHABILITATION (LINING REPAIR).................................................................................................92
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 9 of 92 Definitions Assets Water and wastewater infrastructure owned and operated by Watercare. As specified In reference to quality control check sheet templates, an action of audit to be undertaken if specified by the designer or terms of the contract. Brownfields A land area that has existing or legacy infrastructure, or land that has been polluted. Backfill To refill an excavation created during construction for the installation of pipework, foundations etc. Competent person A person who is qualified because of a specific knowledge, training and applicable experience that is familiar with the Health and Safety at Work Act and conversant in identifying and taking corrective action to potential dangers in the workplace. Controlling authority Person(s) in a position of responsibility that is authorised to make a decision on changes, provide access and provide direction. Embankment An rise above the immediate surrounding land to redirect overland flows, or prevent flooding, or a raised bank to carry roads or railways across low-laying areas. Engineer In reference to quality control check sheet templates, a suitably qualified and experienced person to witness and sign-off on the quality and compliance of the work being audited. The quality control checks do not relieve the requirement for producer statements to be signed by a suitable engineering professional attesting that the works have been constructed in accordance with this construction Standard. ESF Watercare’s engineering standards framework is the single point of access for current standards that allows engineering work to comply with the requirements under the Watercare Bylaw. Equipotential bonding Equalising the electrical potential between an electrical connection and a grounding electrode to metal conductors, such as steel pipes that could become conductive. Fill Human created debris discovered within an excavation. Greenfields A land area that has no prior infrastructure development and is unpolluted. Hazard Potential source of harm. Infrastructure Facilities in an operational capacity that is managed by a controlling authority. Risk Combination of the probability of the harm caused by a hazard and the impact or severity that may result.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 10 of 92 Specific drawings Drawings created to inform specific construction requirements from design basis that are not captured by the standards drawings. Utility A public agency, organisation or entity that is licensed to operate and maintain infrastructure for a public service.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 11 of 92 1. Introduction 1.1 Purpose and Scope This standard has been developed to provide the minimum standard of civil construction work acceptable to Watercare. Additional clauses must be added to contracts where specific site constraints exist. This general civil construction document must be supplemented with standards applicable to the specific operational area (see Section 2). The content of this standard may not be changed or amended. Equivalent or alternatives may only be used on written approval from Watercare. Construction work shall be completed by persons competent in their work possessing a minimum skill and competency level required from this standard. 1.2 Applicability This standard applies to all civil construction work for infrastructure delivered by, or vested to, Watercare. The level of workmanship and quality shall be demonstrated to meet this standard. 1.3 ‘Must’ versus ‘Shall’ versus ‘Will’ Where the verbs must, shall and will (or its past tense forms) are used they describe a requirement for compliance with the statement in which it is used. ‘Shall’ and ‘must’ expresses a mandatory condition or action. ‘Will’ is used to prescribe a performance outcome or intent. 2. Standard documents overview 2.1 Relationship of Watercare standards Watercare standards comprise codes of practices, design standards, standard design drawings, construction standards, and asset and material standards. The Watercare standards sets are requirements additional to nominated national standards, international standards and industry best practice to meet, and in some cases exceed legislative requirements, to accomplish long term operability and good asset management practices to benefit our customers. The interface of these standards with each other and the project specifications are as follows: 2.1.1 Design standards The design standard sets a level of design for particular types of infrastructure based on operational area and associated risk. The design standards provide the minimum criteria for: • Establishing standard design drawings • Interface design between standard drawings and specific design • Establishing the correct sizing of components to meet the baseline parameters of the standard drawings • The basis for developing tailored designs 2.1.2 Design drawings The standard design drawings support the requirements of the design standard. Minimum and maximum criteria are set, and specific standard details are shown. 2.1.3 Asset and material standards The asset standards describe the requirements for asset creation, asset numbering, asset capture, production of manuals and operational documentation. Material standards describe the minimum compliance requirements of materials supplied for asset acceptance. Often selected materials will have limitations of use and requirements specific to the operating environment and infrastructure classification. Section 6 describes
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 12 of 92 the minimum requirements applicable to this standard. Additional requirements may be specified based on the specific design. 2.1.4 Construction standards Construction standards prescribe the methods and requirements for workmanship to be employed when constructing works in accordance with the design requirements, standard drawings and bespoke designs. To achieve the best outcome the construction requirements focusses on proven methods and best practice to ensure quality is maintained to achieve the design life of infrastructure and that maintainability, health and safety and environmental requirements are met. Where construction standards are used or referred to in contracts they form part of the specification of the contract. 2.1.5 Project specific specification These specifications identify site/project specific requirements that are not covered by the normative construction standards or standard design drawings identified during specific design. 2.2 Design build projects Design build projects shall follow the minimum requirements set out in the standard documents for design and construction. 3. Quality control and quality assurance 3.1 Auditing during construction A construction management plan shall identify the quality control points. This standard includes a number of quality control/assurance templates that highlight key compliance checks to be carried out during construction. These quality control templates shall be completed as part of the construction work together with any project specific record keeping requirements for Watercare. The templates provided are the minimum checks that need to be completed and in some instances are required to be completed more than once depending on the type of installation. See Section 4. 3.2 Change orders affecting quality Any change orders for the works shall not compromise quality, safety and regulatory requirements. Any proposed change shall be evaluated against the applicable standard and be demonstrated to comply with the applicable certification and proof of quality documentation. 4. General engineering document submittal requirements All construction work shall have an accepted construction management plan before any work can commence. This document shall identify the overall planning, coordination and control of the construction activities from start to finish. 4.1 Quality control templates The completed quality control or quality assurance sheets shall be provided during the identified stages in the construction management plan. All the applicable quality controls shall be completed and signed-off before Watercare will accept the assets. Items noted as “required” on the QA/QC sheets must be provided or completed and items noted “As specified” is the quantity or requirements that are specified in the particular clauses of construction or referenced standard (whichever takes priority). Certification blocks that are greyed out with “N/A” defines that the item does not apply to the particular party for certification, or that there are no documentation required for the item.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 13 of 92 The QA/QC templates shall be certified to confirm that all actions have been completed by each individual. Refer to Watercare’s compliance policy for work certification to be delivered. 4.2 Documents for commissioning or livening of civil structures The prerequisite for construction work that requires progressive commissioning or livening is to provide sufficient supporting documentation for the safe and effective operation of the parts. Pre-commissioning test results shall be signed-off before commissioning commences. Refer to Watercare Code of Practice for commissioning COP-03. At completion of the construction work the following minimum documentation is required in its final format for handover to Watercare: • Post construction residual risk register • Operation and maintenance manual • As-built drawings (AutoCAD) and survey data • Assets certificates • Material compliance certificates • Engineering producer statements • Construction completion report • Commissioning documentation • Quality control certificates • Compliance certificate (CS3) Specific details of the content of the above documents and templates are available from Watercare’s Data and Asset Information standard, Material supply standard and CAD manual. Note – The above listed documents are required for general civil construction works. Where specific infrastructure is constructed and this standard is supplemented by the specific standard associated with a component, the additional requirements are provided in the specific standard. 5. Referenced standards 5.1 Standards list This standard must be read in conjunction with the Watercare, national and international standards listed below. Where conflict or ambiguity exists this standard shall take precedence. Where there is conflict between referenced standards, the higher level of standard shall take precedence. 5.1.1 Watercare standards ME - General mechanical construction standard MS - Material supply standard 7363 - Watercare CAD manual AI - Data and Asset Information standard HSE – Standard Health and Safety and Environmental practices DW05 - Access structure drawings for wastewater infrastructure DW06 - Access structure drawings for water infrastructure DW07 - Access structures general drawings for public and non-public areas DW08 - Pipelines for wastewater greater than 300mm diameter
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 14 of 92 DW09 - Wastewater manhole drawing set for pipelines 375mm and greater DW10 - pipelines for water greater than 250mm diameter drawing set DW11 - Valve chamber detail drawings for transmission water DW12 - Water stand-alone sampling and rainfall metering DW23 - Cathodic protection mechanical and civil detail drawings COP-03 Code of Practice for commissioning COP-04 Code of Practice for disinfection of water systems 5.1.2 National and international standards Earthworks and roading NZS4402 Methods of testing soils for civil engineering purposes AS1289.6.9.1 Methods for testing soils for engineering purposes – Soil strength and consolidation test – Determination of stiffness of soil – Clegg impact value Approved Code of Practice HSNOCOP 55 Storage of Explosives BS 5930 Code of Practice for ground investigations NZTA F2 (New Zealand Transport Agency) – Specification for pipe subsoil drain construction TNZ B/02 (New Zealand Transport Agency) – Specification for construction of unbound granular pavement layers NZTA M1 (New Zealand Transport Agency) – Specification for roading bitumens NZTA M10 (New Zealand Transport Agency) – Specification for dense graded and stone mastic asphalts Pipe and duct laying AS/NZS 2566 Buried flexible pipelines, Part 2: Installation AS/NZS 2032 Installation of PVC pipe systems AS/NZS 2033 Installation of polyethylene pipe systems AS/NZS 4130 Polyethylene (PE) pipes for pressure applications POP001 Electrofusion jointing of PE pipes and fittings for pressure applications POP003 Butt fusion jointing of PE pipes and fittings – recommended parameters POP005 Packaging, handling and storage of polyethylene pipes and fittings AWWA C209 Cold-applied tape coatings for steel water pipe, special sections, connections and fittings Pipe lining ISO 11298 Plastic piping systems for renovation of underground water supply systems Part 1 – General Part 2 – Lining with continuous pipes Part 3 – Lining with close fit pipes AS/NZS 1516 The cement mortar lining of pipes in-situ AS1012 part 24 Methods of testing concrete – Determination of the tensile bond strength of concrete – Repairs and strengthening systems Concrete AS/NZS 1554 part 3 Welding of reinforcing steel NZS 3104 Specification for concrete production NZS 3109 Concrete construction NZS 3111 Methods of test for water and aggregate for concrete NZS 3112 Methods of test for concrete Part 1 Tests relating to fresh concrete Part 2 Tests relating to the determination of strength of concrete Part 3 Tests on hardened concrete other than strength Part 4 Tests relating to grout NZS 3114 Specification for concrete surface finishes NZS 3121 Specification for water and aggregate for concrete NZS 3152 Specification for the manufacture and use of structural and insulating lightweight concrete AS/NZS 4671 Steel reinforcing materials
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 15 of 92 AS/NZS 4672 part 1 and part 2 Steel pre-stressing materials AS/NZS 3679 part 1 Structural steel – Hot-rolled bars and sections Formwork and temporary works AS 3610 Formwork for concrete AS/NZS 4994.4 Temporary edge protection – Part 4 Perimeter protection screens AS/NZS 5131 Structural steelwork – Fabrication and Erection Painting BS5252 Framework for colour co-ordination for building purposes ASTM D-610-08 Method of evaluating degree of rusting on painted steel surfaces AS/NZS 2311 Guide to the painting of buildings AS/NZS 2312 part 1 Guidelines for the protection of iron and steel against exterior atmospheric corrosion Steel Structures Painting Council (SSPC) Painting manual Volume 1: Good painting practice Volume 2: Systems and specifications Demolition AS2601 Demolition of structures Masonry NZS 4210 Masonry construction: materials and workmanship AS 1316 Masonry cement AS/NZS 2699 part 1 and 2 Built-in components for masonry construction AS/NZS 2904 Damp-proof courses and flashings New Zealand Building Code (NZBC) Plumbing AS/NZS 2845 Water Supply – Backflow prevention devices – Materials, design and performance requirements NZS 4503 Hand operated firefighting equipment AS/NZS 1221 Fire hose reels NZS 7643 Installation of uPVC pipe systems AS/NZS 1477 PVC pipes for pressure applications AS/NZS 3879 Solvent cements and priming fluids for PVC (PVC-U and PVC-M) and ABS pipes and fittings BS 143 and 1256 Threaded pipe fittings in malleable cast iron and cast copper alloy BS EN 877 + A1 Cast iron pipes and fittings, their joints and accessories for the evacuation of water from buildings. Requirements, test methods and quality assurance BS EN 12502-3 Galvanised coatings NZS/BS 1387 Steel tubes for threading to BS21 pipe threads New Zealand Building Code (NZBC) Carpentry AS/NZS 1748 Timber - Stress Graded – Product Requirements for mechanically stress graded timber NZS 3604 Timber Framed Buildings NZS 3602 Timber and Wood-based Products for use in Building New Zealand Building Code (NZBC) Metal roofing New Zealand Building Code NZBC E2/AS1 External moisture 4.0 Flashings 5.0 Roof/wall junctions 6.0 Parapets 8.0 Roof claddings 8.1 General 8.4 Profiled metal AS/NZS 4534 Zinc and zinc/aluminium-alloy coatings on steel wire NZ Metal Roofing Manufacturers Inc: NZ metal roofing & wall cladding code of practice NZS 3604 Timber framed buildings
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 16 of 92 6. Materials 6.1 Material standards Materials shall include all equipment, machinery, components or products used to complete the works. All materials necessary for the work shall be supplied in accordance with Watercare’s material standards. Materials shall be new and suitable for their intended purpose and performance requirements. Machinery and equipment shall be in a good maintained condition and safe. 6.2 Recycled and reused materials Recycled material and material reuse is not accepted unless specifically approved by Watercare. 7. Health and Safety All work shall be conducted in accordance with the requirements of the Health and Safety at Work Act 2015. Watercare requires that all contractors undergo a Health and Safety induction programme provided by Watercare prior to any work progressing. Health and safety is the responsibility of every person. The minimum health and safety requirements set out by Watercare must be adhered to and the documentation and procedures must be of an acceptable standard: • Describe the processes to assure compliance with systems, good practice and legislation. • Provide information to demonstrate that the Health and Safety Management System is capable of managing specific hazards and meeting Watercare minimum requirements. Regulations, approved codes of practice and industry standards or guidelines should be referenced as the basis for hazard controls. • Provide a Health and Safety Management Plan which addresses controls and unique high risk activities or components of the work. • Demonstrate the proposed risk controls are adequate and identify alternatives to further reduce risk. Where administrative controls are used, it must be demonstrated that these are sufficient, robust and how they will be properly managed. • Provide the names of Health and Safety staff and their responsibilities. • Verify that all workers have received adequate training for managing the hazards and risks and undertaking the work safely. • Conduct and record site specific inductions. • Where work is on an existing Watercare facility or asset an Access Authority is required before work can start. Refer to Watercare’s Standard for Health and Safety and Environmental practice (HSE) for a more detailed breakdown of requirements. 8. Asset capture Asset information shall be progressively captured and supplied in accordance with the requirements of Watercare’s data and asset information standards.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 17 of 92 9. Civil construction Work in public areas and road reserve Work in the road reserve shall comply with the New Zealand Code of Practice for working in the road (NZCOP), and the specific requirements of the Auckland Transport Code of Practice (ATCOP). Work in any public area shall require prior written approval by the controlling authority. All requirements for working in the road such as corridor access request (CAR) and traffic management plan(s) (TMP) shall be implemented and maintained. Any person employed to carry out traffic management duties shall hold approved qualifications at National Certificate Level for road opening operations, supervision and traffic management. Work in private property Written confirmation from the private property owner or controlling authority shall be obtained before work commences in any private property. Locations of access ways and fill areas on property(ies) shall be arranged under the entry agreement with the owner of the property. Work in private property shall minimise inconvenience to the occupiers. Any damage by the contractor must be rectified immediately at the contractor’s expense. C1. Site roading This section covers access driveways and areas of paving associated with Watercare facility sites. It does not cover major earthworks or construction of roads that will be heavily trafficked or are in the road reserve. Under these circumstances the Auckland Transport Code of Practice (ATCOP) or New Zealand Transport Agency (NZTA) requirements shall be the default requirement. C1.1 General Construction of site roading shall comply with the NZTA listed TNZ or NZTA specifications as amended by this standard unless shown otherwise on the specific drawings. C1.2 Paving subgrade preparation a) Excavation practices shall comply with Section C2 of this standard. b) The sub-grade shall be backfilled capable of sustaining minimum 110 kPa in the long term without subsidence. The cross-fall shall be finished to the level shown on the drawings. C1.3 Subsoil drains a) Subsoil drains shall be constructed in accordance with NZTA F2. b) Drains shall be of minimum 300mm width with a depth to invert between 250mm to 500mm. c) All drains shall have outlets into cesspits or other stormwater drainage structures. d) Stormwater drains shall not be connected or directed to the wastewater system. e) Filter material shall be scoria chip graded 20 to 7. f) PVC pipes must not be used. C1.4 Basecourse and sub-base a) Sub-base and basecourse shall be constructed in accordance with TNZ B/02. b) Sub-base aggregate shall be GAP 65 spread evenly over the full formation area and compacted to a minimum thickness of 200mm. c) The base course shall be AP40 crushed aggregate to a minimum finished thickness of 100mm. C1.5 Asphaltic concrete a) Asphaltic concrete shall be supplied in accordance with NZTA M10, mix designation DG7. b) Bitumen shall be NZTA M1 approved with an 80-100 penetration grade. c) Construction shall be in accordance with NZTA M10. Layer thickness shall be 30mm. d) The asphaltic concrete shall have a well compacted dense surface, uniformly graded and free from irregularities. There shall be no area where water will pond.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 18 of 92 C1.6 Kerbing Kerbs shall be of minimum 17.5 MPa precast concrete or alternatively cast in situ concrete to a profile that matches existing kerbs or as specified on the specific drawings. C1.7 Stormwater drainage a) Precast cesspits shall be constructed using minimum 25 MPa grade concrete. Cesspits shall be watertight and support the grating at grade. b) The grating and frame shall be standard heavy duty non-roc pattern cast iron, set in concrete. Unless otherwise noted, outlets shall be trapped. c) Gully traps where required shall be compliant with New Zealand standards. d) Unless the material is noted on the specific drawings, pipe and fittings will be selected from concrete, glazed earthenware, polyethylene or uPVC that shall comply with Watercare’s material standards and constructed in accordance with Section C3 of this standard. e) Where stormwater is connected outside the site the construction shall comply with the Auckland Council Stormwater Code of Practice. C1.8 QA/QC template Quality control shall be demonstrated to meet the testing frequency within the production tolerances as set out in NZTA M10. Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Asphalt grading DG7 grade, NZTA M10, Table 3.2 Required Required As specified 2 Binder content Quality control sheet supplied in compliance with Table 1 of TM6003 (Explanatory notes to NZTA M1) Required Required As specified 3 Maximum specific gravity Within limitations set by Table 9.2 of NZTA M10 Required Required As specified Sign-off C2. Earthworks This section covers site clearing, removal and stockpiling of materials, bulk and detail excavation and backfilling for general civil construction works. C2.1 General a) Safe excavation practices shall be followed in accordance with the WorkSafe NZ: Approved Code of Practice for Safety in Excavations and Shafts for Foundations. b) Work shall be carried out in accordance with the applicable resource consents and environmental compliance requirements. c) Finished surfaces shall be formed and set out to the levels as shown on the specific drawings and be free of depressions and loose materials. d) Refer to Watercare Health and Safety and Environmental practices standard (HSE) for discovery protocols or archaeological, anthropological and antiquarian discoveries. C2.2 Site preparation a) Suitable temporary fencing and signage shall be erected that will control overall access to the site as well as entry into specific excavation areas as necessary for the protection of the public. b) The trimming or temporary relocation of trees or shrubs will be undertaken with the consent of the owner of the vegetation. c) Vegetation that requires protection shall be fenced off beyond its drip-line or as otherwise prescribed by the consenting authority prior to earthworks commencing in the vicinity. d) All cleared material shall be removed from the site. Refer to section C2.5 for any stockpile requirements. e) Tree stumps shall be completely removed. Hollows formed by the stump removal shall be backfilled and compacted level with the surrounding area.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 19 of 92 C2.3 Geotechnical investigations a) In some instances Watercare may provide geotechnical site investigation reports or a geotechnical baseline report (GBR). No responsibility is accepted for its accuracy or relevance. This information shall not be considered as complete and shall be supplemented as necessary for the site specific activities. b) All additional investigation locations shall be surveyed and immediately after the investigations are completed backfilled and sealed. c) All additional geotechnical information obtained shall be uploaded to the Auckland Geotechnical Database, at the following location: (https://agd.projectorbit.com/) C2.4 Topsoil stripping a) Topsoil shall be stripped from all areas to be excavated, backfilled or otherwise disturbed as part of the construction works. b) The topsoil shall be stockpiled in an appropriate area clear of the works site activities. c) The depth of topsoil stripped shall be: • At least 300 mm in farmland, residential property or other cultivated areas, or • At least 150 mm elsewhere, or • The full depth of topsoil when less than the above depths exist. • Completely removed from embankments. C2.5 Stockpiling a) Unless required by the conditions of consent or specific requirements, stockpiles shall be held at the site. b) Different material types shall be excavated and stockpiled separately. c) Stockpiles shall be safe and stable with steep faces that allows maximum drainage. d) Silt barriers shall be installed around stockpiles with suitable drainage. e) Stockpiles shall be covered with a suitable geotextile to prevent erosion or covered with grass of minimum 90% covering from a suitable seed mix. f) Materials unsuitable for reuse shall be removed from site and disposed to an appropriate tip site. g) Material inappropriately stockpiled that has become unsuitable for reuse shall be removed and replaced. C2.6 Excavation support and perimeter protection a) Temporary works design shall be undertaken and installed to provide safety for persons working in and around the excavation that complies with Health and Safety regulations. b) The design shall be undertaken (CS1) or certified (CS2) by a Chartered Professional Engineer registered with CPEC for the relevant practice area. c) The temporary works design shall allow for the safe removal of the supports at completion of the works. In exceptional cases where the removal of temporary support poses a risk to adjacent property or structures the temporary works shall be incorporated into the permanent work on prior approval of Watercare. C2.7 Excavation general a) Any excavation work that is notifiable under the Health and Safety at Work Act shall be lodged with WorkSafe New Zealand. Copies of notifications shall be supplied to Watercare. b) Current services plans from all utility controlling authorities shall be obtained and the services located and marked on site. Utility service providers shall be notified in writing of any intention to excavate within the vicinity. c) Unless otherwise shown on the specific drawings no excavation shall be closer than 500mm to any other utility service or any special backfilling material for that utility. For work close to existing Watercare assets the Auckland Council Water and Wastewater Bylaw shall be followed. d) The ground shall be excavated to the minimum depths necessary for the construction. Deeper excavation may be required to secure a firm foundation. The extra depth shall be backfilled either with concrete or an approved hardfill compacted as specified by the designer. e) Foundations shall be prepared with any fissures cleaned and backfilled with all loose materials removed. C2.8 Water in excavations a) Excavations shall be kept free of water during construction with all practicable steps undertaken to prevent water from entering the excavation.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 20 of 92 b) Water discharged from excavations shall be disposed of in a consented manner. All pipework, sub-drains and sumps shall be installed and the pumping plant operated and maintained as necessary to deliver and maintain the excavation free from water. c) Temporary sub-drains or sumps will only be allowed under any permanent work if essential to keep the excavation clear of water. Temporary sub-drains and sumps shall be blocked off and backfilled with concrete until watertight when no longer required. d) The construction methodology shall ensure there is no risk of hydrostatic uplift or ground subsidence as a consequence of the works. e) De-watering consents may be required and shall be adhered to. C2.9 Excavation for trenches a) The width and depth of trenches for pipelines shall be to exact dimensions. b) Additional excavation is permitted at connections and joints to allow safe and efficient working areas when making connections. Where specific design of the trench limits the width between soil faces the excavation shall not exceed the given dimensions. c) Where trenches are constructed in an embankment the stability and integrity of the embankment shall not be compromised. C2.10 Excavation for structures a) Structures include underground chambers, wells, anchor blocks, permanent piles, concrete bases and any other building requiring a ground foundation. The excavation shall be to the lines and levels on the specific drawings. b) The bottom of the excavation or load bearing area shall be of undisturbed material graded and trimmed, or as otherwise specifically designed, to levels on the specific drawings. C2.11 Excavation by hydro-vacuum excavation a) Hydro-vacuum excavation may only be used in small localised areas as an alternative to hand excavation. b) The excavation shall be directed away from bearing surfaces of existing structures to ensure the structural purpose and integrity of the existing structures is not compromised. c) The excavation shall be to a level above the required lines and levels of the design. Hand excavation or mechanical plant shall be used to finish the excavation to the required dimensions. d) The hydrojet or wand shall never remain motionless and may not advance ahead of the vacuum unit so as to cause flooding of the excavation area or washout of adjacent utility service bedding. e) The maximum water pressure for straight nozzles shall be 100bar and for spinning nozzles 200bar. Pressure shall be monitored and the water supply fitted with an emergency shut-off at the wand as well as at the truck connection. f) The hydro-vacuum equipment and operators shall be protected by equipotential bonding. Hydro excavation in the vicinity of energized plant or damaged cables shall be excavated with the infrastructure isolated and where practical de-energised. g) The excavation shall be screened to prevent any flying debris causing harm or damage. C2.12 Excavation by explosive blasting a) Explosive blasting works shall be notified to WorkSafe NZ. A hazard and risk assessment shall be completed and reviewed by Watercare. b) Blasting shall be carried out by the NZQA certificated construction blaster (appropriate level for activity) responsible for the blasting work. c) Storage and handling of explosives shall comply with the Approved Code of Practice HSNOCOP 55 Storage of Explosives. Only daily requirements shall be held on site. d) All charges shall be screened to prevent any flying debris and all necessary steps shall be taken to warn traffic, workers, nearby residents, and the public when shots are about to be fired. e) Evidence shall be provided that the amplitude of ground vibration due to any blast does not to exceed 0.25 mm when measured at a distance of 150m from the seat of the blast. C2.13 Excavation material classification a) Common material: Common excavation shall include material with plastic properties, un-cemented granular materials and slightly cemented materials, such as earth, clay, silt, sand, gravel, peat, sludge and shall include isolated boulders less than 300mm diameter and pockets of strongly cemented material of less than 0.2 m³ per 1 m³ in volume. The soil strength in this category is 25 kPa to 100 kPa with the standard penetration test (SPT) or N value 3 to 20.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 21 of 92 b) Hard ground: Hard ground excavation shall include cemented material such as: sandstone, mudstone, Parnell grit, breccia, volcanic tuff deposits which exhibit strengths ranging from low to high and which require more effort to excavate than common material but which is capable of being excavated with a modern hydraulic bucket in good condition. The soil strength in this category is 100 kPa to 200 kPa with the standard penetration test (SPT) or N value 20 to 49. c) Loose Rock: Loose boulders are greater than 300mm in diameter and with ratio greater than 0.2 m³ per 1 m³ to hard ground or common material. Loose rock also includes intact rock with unconfined compressive strength (UCS) of 1 to 50 MPa that can be effectively broken by rock breakers or loosened by hydraulic bucket. d) Rock: Rock shall be limited to sound, in-situ basalt, greywacke, or argillite, which requires the use of large efficient rock breakers or explosives to excavate. N value is 50 or greater. The unconfined compressive strength (UCS) of intact rock is greater than 50 MPa for this material class. e) Fill: Fill material may be of various grade or material type and is typically found in brownfield areas. The composition and integrity of fill material found other than described in the geotechnical report, shall be referred to Watercare. C2.14 Backfill and fill in general a) Prior to backfilling all forms and debris shall be removed from the excavation. Temporary support works and timbering shall be removed progressively. b) Backfill material capable of compaction to this standard or as otherwise required by the specific drawings shall be used for backfilling. c) Excavated material unsuitable for backfill shall be disposed of as surplus material. d) Suitable backfill material shall be: • Clean fill free of organic matter • Free from hazardous substances or contaminants • Plastic index less than 30 • Capable of achieving the compaction criteria in Section C2.15 e) The backfill placed within 300mm of any structure shall be ordinary surround material (refer section C2.16) unless otherwise specified. C2.15 General compaction of backfill a) Backfill shall be placed in layers less than 230 mm thick in accordance with table C2-1, unless specified otherwise for a specific pipe material. Table C2-1 Compaction requirements Also see requirements for specific installation material that may vary from the below table. Application requiring compacted backfill Modified maximum dry density % Building foundations beneath hardfill 95 Backfill behind walls or chambers 90 Areas of fill in non-trafficked open ground 90 b) Care must be exercised during placing and compacting to prevent displacement or damage of infrastructure and in such a manner as to avoid uneven loading. c) Hand rammers must be used where there is a risk of displacement or damage to infrastructure. d) Hardfill within 300mm of the underside of a concrete floor slab shall be placed and compacted in layers less than 150mm in thickness. e) Hardfill within 100mm of the underside of a concrete floor slab shall be less than AP 20 in size. C2.16 Backfill material classification a) Ordinary backfill: Material free of organic matter, hazardous contaminants and any other substance which prevents satisfactory placing and compaction. b) Ordinary surround material: Ordinary backfill as above but also free of clay lumps and stones retained on a 75mm sieve and not more than 10% shall be stones retained on a 25mm sieve. c) Granular surround material: This shall be imported material, or site excavated crushed and graded stone, graded as for ordinary surround material. Coarse sand or fine scoria may only be used when specified.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 22 of 92 d) Hardfill: Hardfill shall be of granular nature, free of organic matter, hazardous contaminants or other deleterious material. Hardfill shall be approved before placing and may include but is not limited to: Run of pit (ROP), scoria, concrete washings, reject base course and natural gravel. e) Refer to the specific requirements for pipe materials under the pipe and duct laying sections in this standard under section C3. C2.17 Surface reinstatement a) Unless different surface reinstatement is specified in part or whole, the surface of all disturbed areas shall be reinstated to its original condition and matching adjoining surfaces. b) Landowner approval of the reinstatement shall be obtained. c) Roading and footpath reinstatement shall be to the controlling authority’s specification. C2.18 Top soil and grass reinstatement a) Areas to be grassed shall be graded to provide a finished level flush with kerbs and mowing strips or to levels shown on the specific drawings. b) Mowing strips shall be 300 mm wide constructed from 17.5 MPa grade concrete with joints at 2 m intervals. The strip shall be finished off to give a straight even edge and smooth top, level with the final grade of the grassed area. c) Areas to receive grass shall be uniformly relieved by cultivation and ripping. Areas that do not have at least 100 mm of topsoil shall first be uniformly and lightly compacted and evenly graded to 100 mm below finished grade before spreading 100 mm of weed free topsoil. d) Fertiliser (containing three parts superphosphate and one part of sulphate of ammonia) shall be spread at the rate of 50 g/m2 over all areas to be grassed, and the topsoil cultivated to a minimum depth of 75 mm. All sticks, stones, and other debris shall be removed and the area lightly rolled. e) Unless otherwise specified grass seed containing a high proportion of perennial rye shall be sown in suitable weather conditions as prescribed by the supplier at the rate of 35 g/m² and hand raked into the top 20mm of soil. f) Maintenance of the grassed area shall continue until minimum 90% coverage is obtained in all areas. During this period the area shall be watered, weeded, re-sown, rolled and mown as often as necessary. Any undue settlement shall be made good. Once the coverage has been obtained a further application of fertiliser at the rate of 50 g/m² shall be applied. C2.19 Surplus material Surplus material remaining after completion of the work or material removed during construction that will not be reused shall be disposed off-site to an appropriate tip site. C2.20 Record keeping The following records shall be maintained during the work: • Extent of excavation and backfill areas • Type and quantity of excavated and backfill material • Compaction records and the location of tests • Material quantity removed from site with tip site dockets C2.21 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Services located Mark-outs and plans Required Required N/A 2 Clearing and establishment As consented, accepted construction plan N/A Required As specified 3 Topsoil Identified, graded, stored N/A Required As specified 4 Geotechnical investigation Recorded, surveyed, uploaded to AGD, restored Required Required Required 5 WorksafeNZ notification Notifiable works – response from Worksafe NZ Required Required Required
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 23 of 92 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 6 Excavation Material classification, test records and quantity records Required Required N/A 7 Temporary support design CS1, or PS1 if required Required Required N/A 8 Line and level correct (survey), clear of debris and defects Required Required As specified 9 Backfill Temporary support removal plan Required Required N/A 10 Backfill material grading N/A Required Required 11 Plastic index <30. NATA/IANZ test lab results Required Required N/A 12 Compaction test. NZS 4402, Test 5.1.2 and 5.1.4 – NATA/IANZ test lab results, or Clegg hammer impact tests to AS1289.6.9.1 Required Required N/A 13 Compaction test location records Required Required N/A 14 Reinstatement Topsoil replaced to 100mm depth, clear of stones and debris, 90% grass cover N/A Required Required 15 Controlling authority(ies) sign-off Required Required Required 16 Surplus material removed Site inspected. Tip facility records provided Required Required N/A Sign-off C3. Pipe and duct laying a) This section covers the general civil construction of underground pipelines and ducting for Watercare’s services. b) This section does not include mechanical construction requirements for particular requirements of welding, flanges and fittings. Refer to Watercare’s General Mechanical construction standard. c) Where ‘pipe’ or ‘piping’ is referred in this section it shall be read to also mean any pipe or conduit for the purpose of ducting. C3.1 General Pipeline construction a) Subsections for specific construction methods shall be read in conjunction with these general requirements b) Pipe shall be transported and handled according to the manufacturer’s requirements for the specific material type to avoid damage. c) Pipe shall be stacked not more than three layers high or as otherwise specified by the manufacturer’s recommendations and without placing excessive loads on the lower layers. Stacks shall be arranged not to place any load on pipe ends. Pipe supports shall not create point loads on the pipe. d) Pipe ends shall be capped. e) Excess pipe (where supplied by Watercare under contract) shall be returned to the specified Watercare storage facility. f) All non-metallic pipelines shall have an accepted tracer wire installed over the entire length of the installation (refer section C3.1.7) with suitable connecting stations where practicable. Additionally pipe installed by open trenched methods shall have an applicable warning strip e.g. “CAUTION – WATER MAIN BELOW” or an approved equivalent of minimum 100mm width at 450mm above the pipe. The service appropriate colour coding shall be to AS/NZS2648: Service Colour Electricity Orange Gas Yellow Water Blue
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 24 of 92 Service Colour Communications Green Firefighting* White Sewerage Cream Reclaimed water Purple *applies to dedicated fire lines. Reticulation mains with hydrants installed on them shall be blue. g) Trench bedding and pipe surround shall be progressively inspected as the work continues. Pipe shall not be installed before a new section of bedding has been inspected. h) Open trenches shall not progress more than 75m ahead of completely backfilled and sealed section or as otherwise limited by the controlling authority. i) Flexible pipelines as defined by AS/NZS2566 shall be tested for oval caused by superimposed loads and inappropriate sidewall support. On completion of the pipe installation (for any pipe laying technique) the pipe shall be tested by pigging or laser scanning (where more practical for larger diameters). j) On completion all pipework shall be CCTV inspected for defects, in particular pipe joints and to identify ponding areas for correction in gravity systems. C3.1.1 Position tolerances a) Pipe shall be installed to the line and level required on the specific drawings. The position tolerance for pipe laying at any point along the length of the installation shall be within ±30 mm from the specified design. b) Additionally the following specific allowances apply: • No over vertical (causing upstream ponding) for any wastewater or drainage pipeline. • Horizontal directional drilling (HDD) to a maximum horizontal deviation of 100mm. • Pipe jacking, boring or tunnelling to a maximum horizontal deviation of 100mm. c) Pipe penetrations into any structure shall be to the location and tolerances specified on the specific drawings. C3.1.2 Bedding material, pipe surround and compaction a) Filling of bedding and pipe surround material shall be to the dimensions specified on the standard drawings for the appropriate installation area and service type or as otherwise stated by the design specific drawings. b) Bedding and pipe surround material shall be as specified on the standard drawings or as otherwise stated by the design specific drawings (i.e. earthquake resilient design or rigid pipe as per section C3.9). c) Alternative bedding material may be proposed but requires specific approval (must comply with AS/NZS 2566 for flexible pipe or AS/NZS 3725 for rigid pipe). d) Where there is a risk of soil fines migrating into the trench the affected section shall be lined with geotextile. e) Compaction of the bedding and pipe surround backfill shall be 70% of the density index (95% dry density ratio) for cohesion-less soils for both trafficable and non-trafficable areas and is based on the standard detail. f) Compaction shall be as specified when using an approved alternative. g) Pipe deflection shall comply with the standards for flexible and rigid pipe installation and compared against the calculated short and long term deflection for acceptance. h) For concrete encasement the concrete shall be vibrated into position from one side of the pipe only. The concrete shall have a slump value of 180-200mm. Note – the above requirements are for open trench excavation in competent soils. Where an installation technique other than open excavation is employed the specific requirements are described in the applicable section in this standard. The trench design will be based on geotechnical findings during design investigations. Where it is identified that the geotechnical conditions differ, it must be reported to the designer to review the pipe bedding specification to confirm that there is no risk of subsidence, hydrostatic uplift or any other soil conditions that may compromise the pipeline integrity. C3.1.3 Pipe laying in embankment a) Pipe laying in embankments shall be to the specific design requirements.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 25 of 92 b) Where a trench preparation requires over excavation to be corrected and/or where the embankment material differs in type and compressibility from the design conditions the designer shall specify the corrective action. C3.1.4 Pipelines through structures a) Pipes passing through structures shall be thoroughly cleaned and wrapped with an accepted protective coating to the coating manufacturer’s specification. b) The protective wrapping shall be extended minimum 150mm beyond the face of the structure. The following wrapping types shall apply: • Steel or ductile iron: bituminous or petrolatum based • Plastic to steel, or to ductile iron interface: bituminous c) Hydrophilic water-stop seal shall be applied as required for chambers and manholes to ensure there is no leakage between the pipe and the structure. d) Where puddle flanges are installed the wrapping shall be to the base of the puddle flange on each side, not over it. e) Before the pipe is cast in place and after placing any reinforcing steel the pipe wrapping shall be inspected for any defects. The specific design may require pipework to freely move through a penetration. C3.1.5 Parallel pipeline separation a) Parallel pipelines shall have minimum clearances between pipes and any other services or structure as required by Watercare’s design standards. b) Where pipes of different diameters are placed in parallel the clearance required by the larger service shall be observed. c) In brownfield situations passing an obstruction may require a standard clearance to be reduced. Watercare Operations and the other utility owner must be agreeable to the proposed reduction in clearance. The reduced separation must not: • prevent future maintenance and operation, and • not impact structurally on the pipe or obstruction, and • not be longer than 2m. C3.1.6 Vertical separation from other services a) The minimum vertical separation distances between the pipe and any other services or structure shall be maintained as required by Watercare’s design standards. b) In brownfield situations the minimum clearances as required by the design standard may need to be reduced when unknown structures are encountered. Watercare Operations must be agreeable to the proposed reduction in clearance. The reduced separation must not: • prevent future maintenance and operation, and • not impact structurally on the pipe or obstruction. c) The crossing length must be kept as short as is practicable. C3.1.7 Trace wire installation a) A suitable trace wire system from the Material Supply Standard shall be selected, including the proprietary splicing and test point fittings. b) Tracer wire shall be secured to the pipe at three metre intervals. c) When placing a tapping band on the pipe, ensure that the tracer wire is not placed between the pipe and tapping band and provide adequate slack over the fitting. The wire shall be protected from excavation works. d) With exception of approved spliced connections the tracer wire shall be continuous from between valve chambers or connection/trace points. e) No breaks or cuts are permitted. f) Spliced or repaired connections to the tracer wire shall be made using proprietary splice fittings. g) The tracer wire shall be secured to the outside of the valve sleeve and brought up to the valve box to a point 100mm below the surface and an additional 500mm of slack in such a manner as not to interfere with the working of the valve or damage the wire.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 26 of 92 h) The main line tracer wire shall follow hydrant laterals up to and back from the hydrant and then continue along the watermain. i) The testing for functionality will only be undertaken after confirmation that the installation has been completed. j) A test certificate shall be supplied to Watercare on the outcome of the test. C3.1.8 QA/QC template Note – Where an installation techniques other than open excavation is employed the specific requirements are described in the following sections. The general requirements set out above also apply to these other techniques. Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Storage and handling Pipe ends capped, Stacked safely, less than 3 high, pipe ends clear N/A Required N/A 2 Pipe inspection Free from damage. Pipe lining cracks restored (as applicable to pipe material) N/A Required Required 3 Trench installation Warning strip installed N/A Required As specified 4 Traceability Non-metallic pipe with tracer wire, continuity test certified Required Required Required 5 Position Requirements of C3.1.1 N/A Required As specified 6 Pipe through structures Protective wrapping 150mm beyond each face N/A Required As specified 7 Material outer protection, wrapping, joint inspection Coating or wrapping completed as required for the specific material. N/A Required As specified 8 Separation Parallel according to table C3-1 N/A Required Required 9 Vertical crossings Min. 150mm, other services load protected N/A Required Required 10 Pipe oval Pipe pigging or bore scanning to be within acceptable design parameters Required Required Review document 11 CCTV CCTV inspection – Reviewed for defects. Lining repairs completed. Required Required Review document 12 Deflection check Pipe tested for deflection after backfill and compaction to AS/NZS2566. Rigid pipe test at manufacture and compared to installation Required Required Required 13 Testing & disinfection Testing requirements for pressure, non-pressure pipe, or sleeve as appropriate. Refer to Section 10 Required Required Review document Sign-off
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 27 of 92 C3.2 Pipe jacking, boring or tunnelling and shaft sinking This section shall be read in conjunction with section C3.1. C3.2.1 General a) Contractor’s staff shall be appropriately trained and the day-to-day activities of the tunnelling or jacking operations shall be appropriately managed in accordance with the Health and Safety at Work Act, Mining Operations and Quarrying Operations regulations as well as the implementation requirements of Worksafe NZ’s high hazard unit. b) Refer to Watercare Health and Safety and Environmental practices standard (HSE) for discovery protocols or archaeological, anthropological and antiquarian discoveries. The Contractor will monitor the following features during the works which could be symptomatic of a cave presence: • Reduction in telescope station load • Loss of slurry flows and pump pressures through head • Sudden loss of TBM Thrust cylinder pressure and/or cutter head torque • Potential increase in advance speed • Machine pitch decreasing c) The tunnelling or jacking installation design shall be appropriate for the work and the contractor shall include specific risk mitigation plans for Watercare’s consideration. d) Appropriate storage shall be allocated for excavated material. All excavations, headings and tunnels shall be adequately supported at all times. e) Any removal of water during the work shall not cause subsidence, damage to the works or damage to any other property. Once completed shafts and tunnels shall be watertight with no signs of seepage. Any dewatering consents where required must be adhered to. f) Sufficient ventilation shall be provided at all times during construction. g) The type of tunnelling operation method shall be limited to the internal dimension of the pipe tunnel in accordance with the British Tunnelling Society and the Pipe Jacking Association:
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 28 of 92 Table key: Acceptable – undertake assessment of the risks and controls associated with the tunnelling works. Avoid – Requires robust technical assessment to justify the tunnelling technique and deviation from acceptable criteria. Appropriate health and safety controls and risk management shall be in place. Not Acceptable – This technique may not be used under any circumstances. An alternative solution shall be sought.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 29 of 92 C3.2.2 Jacking pits, headings and shafts a) Construction of shafts and chambers required for the works shall be specifically designed to accommodate the tunnelling or jacking method. b) The construction design shall allow for removal and reinstatement as required by this standard. The design shall be provided with CS1 and its implementation by CS4 compliance statements. c) A safe means of access and egress shall be provided. Where any mechanical means is provided, ladder access shall also be provided. d) The base shall be concreted and any segmented joints grouted or annulus filled, refer section C3.2.4. e) Openings in shafts and pits shall only be made after grouting has been completed. All openings shall be engineered and drawings provided. C3.2.3 Installations under roads or other facilities The installation under roads or other facilities must not: • Interfere with the normal operation of the road or facility • Cause any damage, deformation or weakening of the road or facility • Interfere with any other facility or utility service C3.2.4 Over excavation and grouting a) The product pipe shall not be subjected to hydrostatic pressure from the grout or aquifer system during the grouting phase that cannot be withstood by the specified product pipe. b) The contractor shall provide design calculations to show that the anticipated net pressure on the tunnel is less than 2.5 times the critical buckling pressure of the tunnel. c) The grouting process shall not deform the product pipe or dislodge supports and move the pipe from its designed alignment. d) The maximum length between grouting points shall be 30m for augers or jacked pipes and progressive for tunnel boring machines. e) Any gaps between the outside of the pipe wall and the surrounding soil shall be pressure grouted with free flowing filler for the full length of the bore to provide structural support for the tunnel and to seal against groundwater where appropriate for the soil type i.e. competent/self-closing clay soils may not require to be grouted as long as no surface distortion occurs. f) The grout shall have a minimum 100 year life expectancy. C3.2.5 Pipe jacking a) It shall be demonstrated that the jacking loads are less than the maximum loads that the jacking pipe are able to withstand. b) The jacking ram shall transfer load to the pipe through a thrust ring to provide an even load. c) The pipe manufacturer’s permitted draw and angular deflection shall not be exceeded at any pipe joint. d) Cut pipes shall not be jacked. e) Pipe joints shall be true and the jacking load continuously applied to prevent joints from opening when the jacking loads are removed. f) Intermediate jacking pits shall be used to prevent the maximum jacking force being exceeded. The location of the intermediate jacking pits shall be agreed with Watercare in advance. C3.2.6 Micro-tunnelling The micro-tunnelling machine shall be selected in respect of the drive length and soil conditions. Micro- tunnelling shall comply with the above sections. C3.2.7 Reinstatement of jacking pits a) Jacking pits or trenches excavated to install pipe shall be reinstated within seven days of completion of pipe installation operations. b) The order of closing shall be from the tunnelling shield working backwards. The pipe joints in the intermediate jacking pit shall be sealed, the receiving joint face re-packed and the joint closed by jacking the upper-end pipe forward. c) It is not acceptable to form a pipe joint in the intermediate jacking pit with a pipe cut-in.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 30 of 92 C3.2.8 Record keeping The following records shall be maintained during the tunnelling works on a daily basis: a) Daily report: • Progress, time and events • Issues and risks • Special events • Any updated on details for each of the drilling stages - reaming sizes/steps b) Drillers log: • Details for each of the drilling stages - reaming sizes/steps • Drill bit type and size • Torque • Thrust force on pipe • Pump rate and pressure c) Steeling log: • Line and level • Deviation from design C3.2.9 QA/QC template This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Work method statement Accepted to include best practice and regulatory requirements as enforced by Worksafe NZ Required Required Review document 2 Tunnel machine suitability Evaluation against expected soil conditions Required Required N/A 3 Worksafe NZ notification Worksafe NZ certification Required Required Required 4 Tracking system accuracy check Verification to accuracy tolerance per Section C3.1.1 Required Required Review document 5 Construction daily records Section C3.2.8 Required Required As specified 6 Grouting plan Quantity calculation comparison to actual measured Required Required Required 7 Jacking pit/ shaft pit construction CPEng, CS1 and CS4 to meet selected machine requirements Required Required Required Sign-off C3.3 Horizontal directional drilling (HDD) a) This section shall be read in conjunction with section C3.1. b) Contractor’s staff shall be appropriately trained and the day-to-day activities shall be appropriately managed in accordance with the Health and Safety at Work Act and the enforcement requirements of Worksafe NZ’s high hazard unit as appropriate. c) The Contractor shall provide the following items: • Construction and environmental management plan and specifically addressing the risk of frac- outs • Calculations for completing the drilling works and any temporary works • Tracking systems and a description of the system to be used and its appropriateness • Drilling fluid (where required) and cuttings management plan • Contingency plans • Records as per section C3.3.7
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 31 of 92 d) The drill string entrance angle shall be between 8 and 20 degrees. e) The drilling activity will be surveyed and include the use of a wire line steering system to guide the direction of drilling. A surface tracking system may be used where necessary or an alternate method(s) to achieve the designed vertical and horizontal alignment. f) Ballast shall be inserted into the product pipe for neutral buoyancy when submerged in drilling mud that could cause uplift. g) The pipe must be sealed at either end with a cap or a plug to prevent water, drilling fluids and other foreign materials from entering the pipe. h) Pipe rollers, skates or other protective devices shall be used to prevent pipe damage during pull-back and also to eliminate ground drag. Recommended reaming diameters are listed in the following table. Table C3.3-1 Recommended reaming diameters Pipe Outside Diameter (mm) Back – Ream Hole Diameters (mm) 63 75 to 100 90 100 to 150 110 150 to 200 160 250 to 300 225 300 to 350 315 350 to 400 ≥ 315 At least 1.5 times pipe OD C3.3.1 Calculations The calculations will confirm as is appropriate for the drilling technique, soil type and site specific activities that the following has been accounted for where appropriate in the installation methodology: a) The bending radii do not exceed allowable limits b) Pre-installation loads including hydrostatic test loads and self-weight spanning between any supporting structures do not exceed allowable limits c) The installation loads shall consider: i. Bending stresses due to radius of curvature and pipe over bend where required ii. Maximum installation force on the product pipe iii. Stresses due to frictional drag that may be caused by specific soil types iv. Stresses due to torsional force v. Hydrostatic load due to ground water where required vi. Earth overburden loads on pipe installed deeper than 3 meters vii. Loads resulting from drilling fluid and/or grouting where used against annular pressure limits viii. Construction installation loadings do not exceed allowable limits of the pipe (such as demonstrating limited pull force on the proposed machine) C3.3.2 Construction plan The following information shall be submitted with respect to the construction plan: a) Type and capacity of drilling rig to be used on the project, including thrust and rotary torque. The drilling rig pull/push capacity should be at least equal to twice the weight of the product to be pulled or the weight of the drilling rod in the hole, whichever is greater b) Type and capacity of mud mixing system c) Access requirements to site d) Drawing of work site indicating the location and footprints of all equipment, location of entry and exit pits and the location of slurry containment pits e) A listing of any specialised support equipment (if applicable), including sucker trucks and/or pumps for mud recycling f) Down-hole tools and their suitability for the expected ground conditions g) Management of groundwater during drilling and grouting processes h) Construction records including: i. Diameter of pilot hole ii. Number and size of pre-reams iii. Back ream rate
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 32 of 92 iv. Use of rollers, baskets and side booms to suspend and direct the pipe during pull-back v. Pull in rate vi. The number of sections in which the pipeline is to be installed vii. The drill alignment plan in the form of an electronically generated bore plan viii. Drilled bore logs and any computer output data from steering and tracking systems for each part of the works ix. Grouting type and procedure C3.3.3 Tracking systems The appropriateness of the system shall be confirmed for the site specific conditions with the following details: • Type • Operating range • Degree of accuracy C3.3.4 Drilling fluids and cuttings management plan a) An appropriate drilling fluid shall be used to suit the ground conditions during the pipe installation operations. b) Details of any drilling fluids proposed and the estimated volumes to be used are to be submitted to Watercare before any drilling. Drilling fluids to be used shall be environmentally sound and biodegradable. c) Drilling fluid pressures shall be continually monitored by a down-hole data logger to avoid or minimise hydraulic fracturing or over excavation. Care shall be taken in minimising the loss of drilling fluids onto the ground or the environment. d) If hydraulic fracturing, loss of fluid or no returns are discovered the process shall be halted until the issue is rectified. e) Cuttings and spent drilling fluids shall be disposed of properly and shall comply with the local authority regulations. C3.3.5 Contingency plans Contingency plans must be in compliance with national standards, relevant legislation and resource consent conditions and shall be developed for the following: i. In case of spill or surface seepage (e.g. drilling fluids, hydraulic fluids and spoils), including measures to contain and clean the affected area ii. Recovery method in the case of a stuck drill head iii. The remedial treatment of joints, fractures and any other defects in the strata in the event of drilling fluid loss, cuttings loss or groundwater loss during the drilling, reaming and pipe installation processes iv. Correction of ground heave or subsidence C3.3.6 Grouting Grouting shall be in accordance with section C3.2.4. C3.3.7 Record keeping The following records shall be maintained during the drilling works on a daily basis: d) Daily report: • Progress, time and events • Issues and risks • Special events • Any updated on details for each of the drilling stages - reaming sizes/steps e) Drillers log: • Details for each of the drilling stages - reaming sizes/steps • Drill bit type and size • Torque • Pull/thrust force on pipe • Pump rate and pressure f) Steeling log: • Line and level
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 33 of 92 • Deviation from design g) Fluid summary: • Drilling mud volumes, • Viscosity • Weight and density • Sand content • Rheology (PV / YP) • pH • Types and volumes used C3.3.8 QA/QC template This template is in addition to C3.1.8 Quality Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Pre-qualification Work method statement - Accepted to include best practice and regulatory requirements as enforced by Worksafe NZ Required Required Review document 2 HDD plant suitability - Evaluation against expected soil conditions; tool inspection Required Required N/A 3 Construction plan Required Required Review document 4 Pipe load force calculations Required Required Review document 5 Site Setup Worksafe NZ notification Required Required N/A 6 Entry and exit points and angles Required Required Review 7 Pilot Hole Drilling Steering calibration check Required Required Review 8 Pilot bore drill logs – drilling rate Required Required Review 9 Tooling inspection Required Required Review 10 Annular pressure limits set Required Required N/A 11 Pilot hole record - Within allowable tolerance Section C3.1.1 Required Required Review 12 Drill fluid ongoing tests - Test records Required Required N/A 13 Reaming Tooling inspection Required Required N/A 14 Cuttings tracking Required Required N/A 15 Back ream rate calculation - Data logged ream rate corresponds to calculation Required Required Review document 16 Pipe Insertion Review reaming and cleaning logs Required Required Review document 17 Tooling inspection Required Required N/A 18 Insertion loads - Conforms with calculation in item 4 Required Required Review 19 Pipe Testing Gauging record Required Required Review 20 Annulus grouting record (if required) - Measured values compared to calculated quantity. Required Required Review 21 Pipe pull visual inspection - Damage <10% gouge depth Required Required Review 22 Records Provide daily records as per C3.3.7 Required Required Review Sign-off
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 34 of 92 C3.4 Installation of polyethylene pipe a) This section shall be read in conjunction with section C3.1. b) Polyethylene may be installed by open trench excavation or horizontal directional drilling. c) The polyethylene pipe suitability shall be confirmed for the type of installation. Where Watercare is supplying the pipe material, installation method shall be appropriate for the pipe material. d) Pipes shall be visually inspected before installation and shall satisfy the requirements listed in the below table. The delivery dockets and pipe inspection reports are to be submitted to Watercare within two working days of the delivery. Table C3.4-1 Visual inspection requirements Condition Requirement Branding The pipe material, size and SDR details on the drawings agree with the pipe branding. Branding shall be to the Watecare material standards. Out of roundness Within testing standard. Reversion The pipe shall not exhibit strong reversion at the pipe ends. Eccentricity Pipe wall thickness measured at any point with Vernier callipers. Surface finish There shall be no extrusion die marks or spider-lines, or evidence of crazing, flaking, indication of disintegration, pitting, or discolouration. Scratches None on the internal surface. External surfaces shall be free from longitudinal or circumferential sharp scratches deeper than 10% of the pipe wall thickness. e) Watercare shall be advised if any of the pipes or fittings delivered to site do not meet the requirements of the visual inspection. f) Fittings and accessories shall be stored in their original containers or suitable protective bins. g) Polyethylene pipe can expand and contract when exposed to temperature changes. Pipes must not be secured by backfilling until this contraction has taken place and branches and end fittings must not be completed until this time. Where pipelines are installed by HDD the pipe stretch shall have recovered and thermal contraction complete before restraining the pipe. h) Anchor blocks shall be installed as specified by the drawings with a protective polythene membrane to prevent damage to the pipe. C3.4.1 Pipe curving a) Where site conditions and practical restraints of bending large diameter pipe allow, small curvatures in the pipe can be achieved by bending of the pipe barrel. b) The bending radius, Rb for such bends shall be greater than the pipe manufacturer’s allowance as defined by the below equation with a 1.25 factor of safety applied. Rb = minimum bending radius (m) M = bending moment (N.m) Sb = allowable bending stress for the pipe material (MPa) E = Short term Modulus of Elasticity (for PE 100 E=950 MPa) I = moment of inertia (m4 ) Do = Mean pipe outside diameter (m) n = Safety factor (1.25)
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 35 of 92 c) Bends or manholes (for gravity wastewater, drainage and ducts) shall otherwise be installed. Watercare may consider gravity services to be installed on a curve by specific approval, typically where it can be demonstrated to be the best practicable solution and not cause undue maintenance and access difficulties for operational and future replacement purposes. C3.4.2 Pipe bends and fittings Bends and fittings shall be shop-fabricated by the pipe supplier or by an approved specialist fabricator. Fabrication on site is not permitted. Refer to Watercare’s Material Supply standard. C3.4.3 Pipe jointing a) Jointing shall be by fusion butt welding of the material. Electrofusion couplers, mechanical PE couplers or flanges welded to the pipe shall be used only where specified. b) A Work Method Statement (WMS) shall be supplied for the works being undertaken. The WMS must be approved prior to the work commencing, including pre-qualification test weld work.. c) Refer to Section 10.3 for joint testing requirements and methods. Pipes shall be jointed in accordance with the Plastics Industry Pipe Association (PIPA) POP001 for electrofusion methods and POP003 for butt fusion methods. d) For joints by any other mechanical means the mechanical construction standard shall apply. e) Construction welding shall not proceed until the contractor has proven pre-qualification test welds are ductile for each nominated welder and the pre-qualifications are confirmed by Watercare as being acceptable. f) All construction welding shall be undertaken using the same welding operators, welding machines, plant and welding parameters that produced the acceptable pre-qualification welds. Change or substitution of any plant and/or operator requires a repeat of the pre-qualification weld using the new plant and/or operator. g) If a pre-qualification test weld does not meet the acceptance criteria the contractor shall take corrective actions and submit a non-compliance report (NCR) on its findings and the action taken. The welding parameters shall not be changed without written consent. The contractor shall then prepare and test three additional pre-construction test welds at its cost. h) During construction destructive testing shall be undertaken. The number of welds to be removed shall be one in every 20 welds completed (5%) per pipeline or a minimum of 2 whichever is the greater. i) Construction weld samples shall be taken at random, and wherever possible will be taken from the pull- off side of the butt-welding machine to reduce replacement time. j) Where a construction test weld fails destructive testing refer the below flow chart for quality assurance process.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 36 of 92 Chart C3.4.3-1 Destructive testing QA flow chart k) Hand scraping is not allowed. Mechanical peeling tools and pipe cleaning equipment shall be used. l) All jointing shall take place with alignment clamps. The alignment clamps shall be arranged so that there is no stress on the joint area. Where pipe oval of any joint fitting exceeds the manufacturer’s recommendation the pipe shall be re-rounded by a re-rounding clamp. The re-rounding clamp and alignment clamps shall not be removed until the cool time has elapsed. m) The welder's certification number must be stamped on the bead of each butt welded joint. n) Beads shall not be removed unless specified. C3.4.4 Equipment a) Butt welding machine Details of the butt welding machine, including its age and maintenance history shall be provided with the calibration certificate. Calibration of the machine and heater plate shall be completed to the manufacturer’s specification. The butt welding machine shall not be a manual type. The machine shall be capable of logging (and download to MS Excel) the following:
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 37 of 92 • Weld number or identifier • Weld location • Welding machine including model & serial number • Welding operator and certification number • Pipeline label including material type, OD, SDR, the actual mean wall thickness • Date • Time • Ambient temperature • Machine cylinder area and ram ratio • Heater plate area • Software version • Heater plate temperature • Pressure and time parameters achieved: o Drag pressure o Bead build-up pressure and time (P1 & T1) o Heat soak pressure and time (P2 & T2) o Maximum change over time (T3) o Maximum time to achieve weld pressure (T4) o Welding and cooling pressure (P3) o Maximum and minimum bead size after cooling (mm) b) Electrofusion welding control box Details of the electrofusion control box and the data logger shall be provided including their age and maintenance history and evidence that the control box has a current certificate of calibration for Watercare’s acceptance. The electrofusion control box shall be an automatic bar code scanner machine. Calibration of the electrofusion control box shall include calibration and operation checks to the manufacturer’s specification. All electrofusion welds shall be a data-logged recording (and download to MS Excel) of the following: • Weld number or identifier • Weld location • Welding machine • Welding operator and certification number • Pipe and fitting details • Date • Time • The fusion-cool cycle was completed correctly, or • The error code where the fusion-cool cycle did not complete correctly c) Miscellaneous equipment • Petrol chain saws shall not be used to cut PE pipe. Large diameter PE pipe may be cut using an electric chainsaw without the chain oiler operating, or an electric reciprocating saw, or specialised PE pipe cutter. Smaller diameter PE pipe, <300mm OD, shall be cut with a rotary pipe cutter or clean hand saw. • Isopropyl Alcohol (IPA) having a concentration of 95% or greater shall be used for pipe cleaning prior to welding. IPA wipes specifically for PE electrofusion welding or IPA liquid with lint free cotton cloth is accepted. Acetone is not allowed. • Alignment clamps shall be used. The clamp leg shall be 2.5 to 3 times the pipe OD in length with at least 2 clamps on each leg.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 38 of 92 C3.4.4 QA/QC templates This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Work Method Statement Document provided and accepted Required Required Required 2 Pipe inspected No visual damage, eccentricity and dimensions to AS/NZS 4130 N/A Required As specified 3 Welding machine calibration Calibration certification current Required Required Required 4 Training & competency certification of operators NZQA recognised qualification. Current experience in pipe size and type to be welded. Required Required Required 5 Pre-qualification weld test results All welds ductile. NATA/IANZ accredited laboratory test to ISO 13953/4/6, ISO 21751 Required Required N/A 6 Welding data Logging Excel format with required data Required Required Review document 7 Tent/ shelter over welding Site inspections N/A Required As specified 8 Pipe ends sealed during welding Site inspections N/A Required As specified 9 Construction weld test results Ductile. NATA/IANZ accredited laboratory test to ISO 13953/4/6 Required Required Review document 10 Clean working space, no mud or standing water on trench floor Site inspection N/A Required As specified Butt weld specific 11 Butt Weld parameters Calculated by pipe size and type Required Required N/A 12 Heater plate manual readings (4 per day) Daily checks completed – forms supplied Required Required N/A 13 Weld beads inspected (butt welding) Tolerances to POP003 N/A Required As specified Electro-fusion joint specific 14 Pipe surface preparation Using mechanical peeling tool (no hand-scraping) >0.2mm < 0.5mm material removed N/A Required As specified Sign-off
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 39 of 92 Daily Heater Plate Temperature QA Check Sheet Contract No. Date: Welder: Time Time Pipe Size Pipe Size Show position of pipe and temperature check locations Show position of pipe and temperature check locations Temperature at Position °C Temperature at Position °C 1. 2 1. 2 3 4 3 4 Time Time Pipe Size Pipe Size Show position of pipe and temperature check locations Show position of pipe and temperature check locations Temperature at Position °C Temperature at Position °C 1. 2 1. 2 3 4 3 4
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 40 of 92 C3.5 Repair of polyethylene pipe a) This section shall be read in conjunction with the requirements for the installation of polyethylene pipe (section C3.4) and the material and mechanical standards applying to the specific repair solution. b) The repair of PE pipelines may be achieved using butt welding, electrofusion welding and PE mechanical connectors. Generally butt welding is unsuitable in most repair situations and is more practical for off-site fabrication of repair pieces. c) The type of failure shall be identified before affecting a repair. The repair method must be approved by the Watercare. The typical failure modes and repair solutions are: Table C3.5-1 PE repair solutions Type of Failure/Damage Acceptable Repair 1 Very small scale mechanical damage - surface gouge or abrasion Electrofusion repair saddle 2 Damage at high point where control of water in pipeline not a concern Cut-out damaged section of pipe and replace using PE pipe spool and electrofusion couplers 3 Mechanical damage - such as excavator strike Cut-out short section of pipe and replace using electrofusion flange adapter, or mechanical flange adapter 4 Pinhole leak Cut-out short section of pipe and replace using electrofusion flange adapter, or mechanical flange adapter 5 Broken butt-weld Cut-out short section of pipe and replace using electrofusion flange adapter, or mechanical flange adapter 6 Large scale mechanical damage - such as pipe scoring Cut-out affected section of pipe and join-in new pipe spool using electrofusion flange adapter, or mechanical flange adapter 7 Brittle cracking including slow crack growth (SCG) failure Cut-out affected section of pipe and join-in new pipe spool using electrofusion flange adapter, or mechanical flange adapter d) For any welded type repair the pipe shall not be backfilled or returned into service before the required cooling time has lapsed. e) It is preferred that joints are repaired by butt or electrofusion welding. Non-welded joints shall be flanged or use an accepted proprietary self-restrained product used. f) The repair solution class and pressure rating shall be the same or greater than the existing pipe. C3.6 Installation of welded steel pipelines Steel pipe may be installed by various methods depending on the purpose of the pipe. The requirements in this section apply to the permanent installation of steel pipe for purposes other than unprotected or sacrificial sleeves, in a trench or above ground. C3.6.1 Pipe bends and other assemblies a) This section shall be read together with the mechanical construction standards. b) Any tapers or bends shall be constructed to the dimensions as specified by the drawings for steel pipe assemblies. c) Pipe internal linings or external corrosion protection shall be of the same parent product as the main pipeline or similar accepted alternative according to the operational requirements. d) Linings and external corrosion setback shall allow for site installation and jointing. C3.6.2 Pipe joints a) Socket and spigot joints shall be drawn fully home using safe working practices that do not deform the pipe or damage internal linings.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 41 of 92 b) A full fillet weld structurally joining the pipes shall be made externally and internally (pipelines >700mm), in accordance with the standard drawings and the mechanical construction standard. No person shall enter any pipe for internal work where a body needs to fully enter the pipe on pipes less than 700mm internal diameter. c) Where it is necessary to deflect a joint the maximum deflection for steel pipe socket and spigot joints is listed in the table below: Table C3.6.2 -1 Allowable spigot and socket joint deflection Nominal bore (NB) mm Maximum deflection angle (degrees) 150 7 200 6 250 5.5 310 5 390 5 470 4.5 550 4 630 4 700 3.5 730 4 760 4 810 4 910 3.5 1070 3.5 1300 3 1500 3 1700 3.5 1900 3 d) Pipe assemblies without a formed spigot and socket shall be installed using welding bands in accordance with the standard drawings or as otherwise directed by the specific drawings. e) Flanges and isolation joints or other mechanical couplings shall only be installed in accordance with the design drawings. For details of forming mechanical joints the mechanical construction standard shall apply. f) Access manholes to Watercare standard design shall be installed on pipework of 700mm diameter or larger to facilitate safe access to complete internal pipe welding. The location of access manholes shall be at the discretion of the contractor and stated in the work method statement. The frequency and type of access manhole used shall be submitted to Watercare for acceptance. g) The internal pipe lining shall be repaired for all pipe joints where the steel is exposed. Any rust, loose paint or other deleterious matter shall be removed. Repairs (epoxy and mortar compliant with AS/NZS4020) shall be completed in accordance with the lining product instructions. Where concrete lining is used the repair shall be smooth and continuous with the original lining either side of the joint. h) Concrete lined pipes smaller than 700mm in diameter, or where the pipe joint cannot be reached for internal repair without entry, shall be repaired by other means. Solutions may include that the internal joint be prepared with an accepted rapid setting mortar before the joint is closed or where welding bands are used a temporary inflator expanded against the joint allowing the lining to be repaired by external injection of the grout. Accepted proprietary internal joint repair products or the use of robotics may be other solutions. C3.6.3 Corrosion protection a) Internal coating or lining shall be applied in accordance with the applicable material supply standard for the specified service application. b) Concrete lining repairs shall be made to any cracks, defects or weld joints where the concrete lining separation is greater than 1mm. An accepted product shall be used that is fully tested to comply with AS/NZS 4020. Refer to section C3.6.2 g), h) for internal lining repair at pipe joints.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 42 of 92 c) An accepted tape coating shall be used as external protection for buried pipe and pipe assemblies and be applied in accordance with the product manufacturer specification. Pipe lengths shall be factory wrapped. Pipe assemblies shall be wrapped by the fabricator. Only joints, site installed fittings or repairs shall be wrapped on site. d) The construction and quality assurance for the tape coating systems shall comply with the requirements of AWWA C209 except: • Apply primer to the bare steel surface and overlapping 150mm over the existing wrapping • The tape shall be applied in a smooth wrinkle free coating with a minimum spiral overlap of 67% to achieve three layers e) External epoxy coating for exposed pipe shall be factory applied for pipe lengths. Pipe assemblies shall be prepared and painted by the fabricator. Surface pipe shall be epoxy paint coated to the applicable painting standard. (See section C5) f) Where pipe transitions from buried to painted pipe above surface an ultraviolet resistant protective tape system shall be applied with an overlap of at least 150mm below ground onto the buried protective wrapping, extending to 500mm beyond where the pipe is clear of the buried surface. g) Direct current voltage gradient (DCVG) integrity testing shall follow visual inspection. Any holidays found shall be repaired and retested. Refer to Section 10.12 for testing requirements. C3.6.4 Concrete lined steel pipe - Wastewater specific requirements a) Minor grading deflection shall be achieved within the spigot joint or welding band allowable tolerances. b) Pipe bends are only allowed for pressure systems. Directional change for gravity systems shall be through a wastewater manhole in accordance with the standard drawings. C3.6.5 QA/QC templates This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Socket deflection Within limitations of table C3.6.2-1 (measure/survey) (per joint) Required Required N/A 2 Weld band, socket and spigot joint test Nitrogen/air test pipe ≥700mm test record (per joint) Required Required Review document 3.1 Corrosion protection 3 layer overlap (67% per lap) N/A Required As specified 3.2 Pull test as per AWWA C209 Required Required Review document 3.3 Visual inspection N/A Required As specified 3.4 DCVG survey test results Required Required N/A 4 Components for use with potable water AS/NZS4020 compliant Required Required N/A Sign-off C3.7 Installation of PVC pipelines a) This section shall be read in conjunction with section C3.1. b) Pipe delivered to site shall be checked for any damage and completeness (gaskets in place). The pipe class and dimensions shall be confirmed to be in accordance with the specific drawings and the applicable material standard. c) PVC pipe shall be protected from ultraviolet exposure. d) Particular care shall be taken to prevent seals being exposed to heat, oil, grease or other contaminants. C3.7.1 Pipe Joints a) Pipe joints shall be made to the manufacturer’s requirements. b) Pipe may be cut using a power handsaw or a clean hack saw.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 43 of 92 c) The end of the pipe shall be bevelled at 15ᵒ for 50% of the pipe wall thickness with a purpose bevelling tool or fine wood rasp. The bevel shall be consistent around the pipe circumference and free of any burrs. d) An accepted lubricant shall be applied to the joint in accordance with the manufacturer’s requirements. Lubricants shall be compliant with AS/NZS4020. e) The pipe joints shall be aligned vertically and horizontally driving the joint in. The bar-and-block method shall be used to make the joint. On large pipe diameters mechanical assistance may be required. Reference lines shall be used to prevent excessive force and to ensure the joint is fully home. C3.7.2 QA/QC template This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Pipe joint lubricant Compliant with AS/NZS4020 Required Required Required 2 Socket preparation Pipe bevelled and free of burrs N/A (per joint) Required As specified 3 Socket witness marks Joints drawn fully home N/A (per joint) Required As specified Sign-off C3.8 Installation of Ductile Iron (DI) pipe a) This section shall be read in conjunction with section C3.1. b) Pipe delivered to site shall be inspected for defects including but not limited to lining and external coating defects, gasket condition (spigot jointed pipes) or conforming flange requirements and cracks. c) Pipe protective coatings shall be holiday tested. Repair to any defects identified shall be corrected in accordance with Section C3.6.3. C3.8.1 Pipe Joints a) Pipe joints shall be made to the manufacturer’s requirements. Where other mechanical joints, in particular flange joints are approved by Watercare, please see the mechanical construction standard jointing requirements. b) Spigot and socket joints shall be installed with the socket (bell) facing the direction of installation. The end of the pipe shall be bevelled at 15ᵒ for 50% of the pipe wall thickness. The bevel shall be consistent around the pipe circumference and free of any burrs. c) An accepted lubricant shall be applied to the joint in accordance with the manufacturer’s requirements. The pipe joints shall be aligned vertically and horizontally before driving the joint in. The bar-and-block method shall be used to make the joint. On large pipe diameters mechanical assistance may be required. Reference lines shall be used to prevent excessive force and to ensure the joint is fully home. d) Mechanical joints shall be fitted in accordance with the manufacturer’s requirements and protected against corrosion as per Section C3.6.3. C3.8.4 Pipe deflection with spigot joints a) Where pipe is required to be deflected over a long radius the deflection may be achieved in deflecting the spigot joints. b) The installation of the joint shall be straight as per Section C3.8.1 and the deflection only applied once the joint is fully drawn. c) The deflection shall be applied to the manufacturer’s recommendation. In the absence of manufacturer data the following formula shall be applied as a guideline:
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 44 of 92 R = L/( 2 tan Ɵ/2) Where: R = Radius of curve (metre) L = length of pipe (joint to joint in metre) Ɵ = Deflection angle (degrees) Allowable angle deflection angle per joint Nominal pipe size (mm) Deflection angle Ɵ (degrees) 80 5 100 5 150 5 200 4 250 4 300 4 350 3 400 3 450 3 500 3 600 3 700 2 800 2 900 1 1000 1 d) All joints must be checked on site to ensure that joint seals make full contact and are fully functional. C3.7.2 QA/QC template This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Socket preparation Pipe bevelled and free of burrs N/A (per joint) Required As specified 2 Socket witness marks Joints drawn fully home N/A (per joint) Required As specified 3 Corrosion protection Holiday testing for coating defects. Defect repaired N/A Required As specified Sign-off
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 45 of 92 C3.9 Concrete and Ceramic pipes (Wastewater only) C3.9.1 General a) This section shall be read in conjunction with section C3.1. b) Pipe joints shall be made to the manufacturer’s requirements. c) This section covers concrete pipe for wastewater application, both gravity and pressure applications. d) Pipe delivered to site shall be inspected for defects. Damaged or broken pipe shall not be accepted. e) Pipe may not be unloaded by rolling to ground or similar that would result in impact on the pipe. f) Pipe shall be kept clean. g) Rubber rings shall not be stored in sunlight and care shall be taken with storage to prevent deformation. C3.9.2 Cutting of pipes a) The cut shall be made using a diamond or abrasive saw. Explosive or impact chisel methods shall not be used for cutting pipes. b) The whole cut shall be in the same plane through the full thickness of the pipe wall, and shall be within a tolerance of 6 mm from the true cut line. c) Pipe reinforcing shall be cut cleanly and flush with the finished concrete surface. C3.9.3 Pipe Laying a) Bedding requirements shall be in accordance with the standard drawings for concrete pipe. Unless otherwise shown on the specific drawings, the bedding shall be Type H2. b) Concrete bedding shall be in accordance with the requirements in section C4: • Concrete need not be weight-batched. • Curing is not required. c) The surround material shall be placed as soon as possible after the pipes have been inspected, any concrete bedding has attained sufficient strength and the testing requirements have been complied with. d) Compaction and backfilling shall be to the general requirements. C3.9.4 Laying on a curve a) Pipe laying on curves shall be as specified or shown on the specific drawings. b) Pipe joint shall be to the manufacturer recommendations. c) Where pipes with rubber ring joints are to be laid on curves and the curves are to be taken up in the joints, each pipe shall be entered and pushed home with the pipe in line with the previous pipe. The deflection required to make the curvature shall be made by moving the free end by the required amount. C3.9.5 Rubber ring joints Rubber ring joints shall be made to the pipe manufacturer’s requirements, and: • Out of alignment joint shall not be forced, but parted and remade. • Joints shall be inspected to ensure the rubber ring is in its location (checked with a feeler gauge) and free of twists. C3.9.6 Mechanical joints Mechanical joints shall be installed in accordance with the mechanical construction standard. All joints shall be wrapped with an accepted corrosion protection system. C3.9.7 Repair Refer to section C4.7 for repair and rehabilitation of concrete pipe for wastewater applications.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 46 of 92 C3.9.8 QA/QC Template This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Pipe inspection Free from damage. Seals stored appropriately N/A Required Required 2 Pipe cutting 6mm tolerance N/A Required As specified 3 Pipe laying Bedding type as specified (per section). Type H2 normative if not specified N/A Required As specified 4 Laying on curve – under approval and to the required standard method N/A Required As specified 5 Joints Fully drawn, inspected for defects N/A Required As specified 6 Mechanical joints wrapped to manufacturer requirements N/A Required As specified 7 CCTV CCTV inspection – Reviewed for defects Required Required Required 8 Testing & disinfection Testing requirements for pressure or non-pressure pipe as appropriate Required Required Required Sign-off C3.10 Pipe structural lining C3.10.1 General a) A pre- and post-lining close circuit television (CCTV) inspection shall be completed. b) The pre-lining CCTV assessment shall be to confirm the pre-replacement condition and to verify the lining solution. c) Lining solutions with any compounds or lubricating systems used in potable water applications shall be fully tested to comply with AS/NZS 4020. C3.10.2 Access a) Siting of access locations shall be provided for Watercare’s consideration as part of the construction management plan. b) Where access is obtained through chambers, existing lids or similar infrastructure, best care shall be taken to retain these for re-use. c) The pipeline shall be accessed on approval and only after shutdown is confirmed by Watercare. A minimum of five working days’ notice is required prior to any shutdown, but may be extended due to operational constraints. C3.10.3 Pipeline cleaning a) Cleaning prior to CCTV shall only be completed where sediment deposits are likely to obscure defects. Cleaning methods may include: • Water scour • Air scour • Swabbing or pigging • Water jet b) The construction management plan shall include any cleaning method limitations considering the pipe material, class and expected condition to conserve the pipe’s integrity. C3.10.4 CCTV requirements a) The CCTV shall be produced in accordance with the Watercare Data and Asset Information standards for inspection and collection of data.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 47 of 92 b) Survey logs shall be provided identifying all visible defects, including measurements of the existing lining thickness on the vertical and horizontal axis at each end of each pipe section. C3.10.5 Pipe repairs a) Prior to the relining of each section, where a section of pipe has been removed at a fitting, a single pipe section shall be provided to make up the whole distance between the fitting and the end of the pipe. b) The installation of replacement pipe sections is not required where it is demonstrated that the liner system shall fully withstand all internal and external loads. c) In the case of steel or ductile iron pipe the acceptable protective wrapping shall be applied to the manufacturers’ instruction or as otherwise amended by the general construction standards. C3.10.6 Polymer lining methods a) The polymer lining method shall be appropriate for the pipeline faults. The lining material shall be fully structural. Methods for pressure water applications are: • Swage lining • Cure in place pipe (CIPP) • PE slip lining • PE fold and form b) Unless specified, the contractor shall provide the following information based on the selected lining type: • Hydraulic, soil and dynamic loads • Lateral consideration resulting from adhesion to the host pipe • Material type selection in accordance with the above loading criteria • In the case of slip lining the annulus grouting procedure c) Connections and joints: • Joints shall be welded between connection points. • The welding practices shall be in accordance with the general construction standard for the applicable material type. • Connections such as tees, bends or valves shall be with a purpose adaptor for the lining type. • Connections made with ductile iron or steel are permissible on the condition that the joint between the host, lining and new fitting provides the desired structural integrity. C3.10.7 Cement and mortar in-situ lining methods a) For wastewater applications refer to Section C4.7. b) The cement mortar lining shall be machine applied to 10mm thickness with an allowable variance of ±1.5mm. c) Any fittings attached to the pipe shall be prevented from blocking, and where able, the lining shall be hand finished. d) Any hand reinstatements of fitting connections or small patch repairs shall be within 24 hours of the machine application. Where the machine accessed the pipe, the machine application shall be fully completed with the machine, cut back 75mm and hand rendered. e) The mortar lining shall be allowed a minimum of 72 hours curing time. f) Steel pipe that has been cut open shall be prepared with an acceptable high heat resistant mortar that will seal the mortar behind the weld. This mortar shall be allowed to cure according to the manufacturer’s recommendation before completing the weld. Surface preparation: The cleaning effort shall be such that the pipeline is a bare surface without any loose debris or rust. Concrete lined pipe shall be cleaned without damage to the existing concrete or concrete lining. C3.10.8 Record keeping a) The record form shall be completed per component rehabilitated or in the case of pipelines between access points, batches or shifts. b) Records for polymer lining systems shall follow the requirements for the material type within this standard. For mortar lining the following template shall be used:
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 48 of 92 Structure information Contractor Installation site identifier Asset ID Address Access location Grout mix Date Time Manufacturer batch number Mix composition Mix Volume C3.10.9 QA/QC Template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 CCTV - start Records evaluated against design stage records Required Required Required 2 Pipe cleaning AS/NZS 1516 preparation for lining. N/A Required As specified 3 Product compliance Watercare material standards Required Required Required 4 Mortar application records Min. 10mm, ±1.5mm. Required Required Review document 5 Testing Samples to AS 1012 part 24, tensile bond strength (mortar lining) Required Required Review document 6 Pressure testing and weld samples as per the general civil standard Required Required As specified 7 CCTV – final U3 finish. No visible slumping or cracking Required Required Required Sign-off C3.11 Pipelines brought into service a) All construction test certifications and required operational documentation shall be provided before applying to bring the pipe into service. b) The pipe shall then be leak tested and made ready for final connection. For more information refer to the Watercare Code of Practice for commissioning. Note – Where disinfection of pipes are required before making the connection, the disinfection and testing shall be done as part of bringing the pipe into service due to chlorine retention times. See Watercare’s code of practice for water reticulation disinfection. c) A method statement for final connection works shall be provided for acceptance a minimum of four weeks before the programmed cut-in. d) The method statement shall include but not be limited to: • Position of “stop-ends” to minimise the length of untested section when making the final connection • Test water source and disposal • Plant, equipment and resources to be used • Programme • Lines of communication
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 49 of 92 C4. Concrete C4.1 Construction of reinforced concrete structures a) Where concrete is used in conduits, water retaining structures and manholes, the provisions of NZS 3106 shall apply. NZS 3106 will take precedence over NZS 3109, where there is conflict. No calcium chloride shall be used in reinforced concrete. b) Concrete mix shall achieve 28 day strength of 30MPa unless otherwise specified. c) The ratio of 7 to 28 day strength shall be as specified but not less than 1.3 (or 60% of 28 day strength). d) Construction shall not progress if the 7 day test indicates concern of achieving full 28 day strength. e) Where concrete is used in conduits, water retaining structures, manholes, sewage chambers and wet wells or where concrete is in contact with the ground, the water-cement ratio shall not exceed 0.5. f) Air entrained concrete shall not be used in lifts greater than 2.5m. Concrete shall be placed in its final position within 1½ hours of cement introduction to the aggregates. The time lapse for concrete handling from the mixer or agitator truck shall not exceed 30 minutes. g) Concrete pumping shall follow the contractor’s methodology, designed task specifically and as accepted by Watercare, observing the following: • Aluminium pipes shall not be used • A lubricating mortar run to waste shall be used at the pump start • Slump test at the supply hopper and placement end pipeline • Concrete compression test samples shall be taken at the placement end h) In addition to Clause 7.7.1 of NZS 3109, should rain threaten an exposed concrete pour, suitable covers shall be put in place before the pour commences. i) Curing compounds shall only be used where specified, less than 6 hours after screeding to the manufacturer’s requirements and shall restrict the loss of water to less than 0.55 kg/m2 in 72hours. C4.1.1 Reinforcement a) Reinforcing shall be inspected and certified in accordance with the supply standard before installation and before concrete is placed. b) Reinforcement shall be placed straight between specified bends. c) All deformed bar reinforcement, noted on the drawings as either H or HD followed by the bar size, shall be Micro Alloyed manufacture Grade 500 ductility Class E to comply with AS/NZS 4671 carrying the SEISMIC 500E MA identifier. d) Plain round reinforcing, noted on the drawings as R followed by the bar size, bar shall be Grade 300 complying with AS/NZS 3679.1 e) Pre-stressed reinforcing shall comply with AS/NZS 4672 to the specific design. f) Approval to weld reinforcement is required in every case and drawings shall be included with each application for approval showing the position and type of each weld. Welds shall be in compliance with AS/NZS 1554 part 3. Welds shall be more than 10x bar diameters from bends. g) In addition to the requirements of NZS 3101 and NZS 3190, the manufactures instructions with respect to the bending and re-bending of steel shall be strictly followed. Details can be found at www.reinforcing.co.nz. h) The concrete cover to steel reinforcement shall be the greater of: • The values given in NZS 3101:Part 1, or • the values given in the tables below (design life specific, normally 100 years), or • the cover shown on the drawings.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 50 of 92 Table C4.1.1-1 Minimum required cover for a specified intended life of 50 years Exposure classification Cement binder type Specified compressive strength fc’ (MPa) 25 30 35 40 45 50 60-100 Minimum Required Cover (mm) Al GP, GB or HE 25 20 20 20 20 20 20 A2 GP, GB or E 35 30 30 25 25 25 20 BI GP,GB or HE 40 35 35 30 30 30 25 B2 GP,GB or HE - 45 40 35 30 30 25 C(1) 30% FA - - - 60 60 60 55 C(1) 65% GBS - - - - 50 50 50 C(1) 8% MS - - - - 60 50 50 Notes: 1. For zone C the total binder content shall be equal to or greater than 350kg/m3 and water to binder ratio shall not exceed 0.45. The minimum cover for the C zone shall be 50mm. Table C4.1.1-2 Minimum required cover for a specified intended life of 100 years Exposure classification Cement binder type Specified compressive strength fc’ (MPa) 25 30 35 40 45 50 60-100 Minimum Required Cover (mm) Al GP, GB or HE 35 30 30 30 30 30 25 A2 GP, GB or E 50 40 40 35 35 35 30 BI GP,GB or HE 55 50 45 40 40 35 30 B2 GP,GB or HE - 65 55 50 45 40 35 C(1) 30% FA - - - - 70 60 60 C(1) 65% GBS - - - - 60 50 50 C(1) 8% MS - - - - - 50 50 Notes: 1. For zone C the total binder content shall be equal to or greater than 350kg/m3 and water to binder ratio shall not exceed 0.45. The minimum cover for the C zone shall be 50mm. Abbreviations used in the above tables are as follows. (Refer to NZS 3101: Part 1 for full definition) FA fly ash GB general purpose blended cement HE high early strength cement MS amorphous silica GBS ground granulated iron blast furnace slag i) The minimum cover for a surface in contact with the ground shall be 75mm, or 50mm if using a damp proof membrane between the ground and concrete. j) Unless otherwise specified, the cover required for exposure classification B2 with an intended life of 100 years shall be used. C4.1.2 Construction joints a) Construction joints shall be in continuous unbroken lines. Unless otherwise specified construction joints shall be as shown on the specific drawings. b) In water retaining structures, immediately before placing the new concrete on a horizontal joint the roughened surface shall be primed with a neat cement grout layer of 5mm thickness and a water cement ratio less than 0.32. c) Any alternative joint surface preparation shall be subject to approval. C4.1.3 Contraction joints a) Contraction joints shall be formed where specified.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 51 of 92 b) In water retaining structures the joints shall incorporate an appropriate water stop unless otherwise specified. c) The surfaces of contraction joints shall be left smooth. Where details of contraction joints are not shown on the specific drawings a tapered rebate shall be formed in the joint. The taper will have an average width of one third of the thickness of the concrete and a depth of not more than half the width. C4.1.4 Slump tolerance For water retaining structures, slump tolerances shall be half those given in Table 9.1 of NZS 3109. C4.1.5 Vibration Internal vibrators shall be on approval. If scum, devoid of coarse aggregate appears on top of or ahead of concrete after specified compaction (Clause 7.5.5 of NZS 3109), the laitance layer shall be removed to waste and replaced with concrete and before any consecutive layers are placed. C4.1.6 Surface finish Formwork, concrete proportions and workmanship shall be such that no patching of concrete surfaces will be required. The minimum standard of surface finish shall be as indicated in the table below. A uniform finish standard shall be provided to any designated location. Table C4.1.6-1 Minimum standard of surface finish Location Surface finish Concealed foundation surfaces F1 Top surface of foundation pads U2 Visible foundation surfaces F5 Site concrete U1 Interior walls F3 Exterior walls F5 Floor and roof slabs U2 Formed concrete to take plaster F2 C4.1.7 Penetrations through structures a) All embedded items shall be accurately set and supported in place until the concrete has set. In addition to Clause 5.5 of NZS 3109: • Place such pipes or items in the forms before placing the concrete, or • Provide approved block-outs in the forms • Position penetrations on construction joints to minimise shrinkage cracking where feasible • Construction joints around block-outs shall have approved keys formed and/or be roughened to an amplitude of 5mm • Block-outs shall be shaped to allow removal of all air displaced by the subsequent grouting of the penetration b) When grouting in pipes and other items, concrete grout (or approved alternative) of at least equal strength to the surround concrete shall be used. An acceptable expansive admixture, applied in accordance with the manufacturer’s instructions shall be used in the grout to ensure a watertight joint. c) Penetrations for pressure rated pipe (other than thin walled sleeves) shall be sealed against water ingress with an overlapping strip of an acceptable hydrophilic sealant encased at least 70mm in the concrete casting. d) Penetrations to the structure shall be grouted in place by placing the grout under a head of at least 100 mm. The concrete shall completely fill the spaces to achieve the same water tightness as the rest of the structure. e) Pipes less than 75 mm diameter in cored holes shall be fixed in place by dry pack mortar or cement grout with a suitable bonding agent. C4.1.8 Records In addition to Clause 303.1 of NZS 3104, the mix design shall be identified and any admixtures shall be included on the delivery docket.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 52 of 92 C4.1.9 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Concrete construction plan Including delivery scheduling plan to meet timeframes Required Required N/A 2 Confirm required concrete strength As specified or minimum required from this standard Required Required Required 3 Reinforcing inspection According to specific drawings Required Required Required 4 Deformed bar SEISMIC 500E. Test certification of steel required Required Required Required 5 Plain bar grade 300. Test certification of steel required Required Required Required 6 Welding 10x dia. from bends Required Required Required 4 Formwork Cover requirement met, Tables C4.1.1 -1/2 Required Required Required 5 Concrete plant certification Certification graded ready mixed concrete plant to NZS3104 (High grade or special grade) Required Required Review document 6 Vibration Witnessed to comply with requirements of NZS3109, any laitance replaced N/A Required As specified 7 Test reports Supply source Required Required N/A 8 Mix identification and compressive strength Required Required Required 9 Location of structure Required Required N/A 10 Batch number Required Required N/A 11 Time and date Required Required N/A 12 Time prepared Required Required N/A 13 Slump 0.5x values of table 9.1, NZS 3109 Required Required Required 14 7 day test Required Required Required 15 28 day test Required Required Required 8 Construction and contraction joints Inspected as per drawings N/A Required As specified 9 Surface finish Table C4.1.6-1 N/A Required As specified 10 Testing tanks and reservoirs Complete test to Section 10.5.4 Required Required Required Sign-off C4.2 Construction of enclosed chambers, manholes and small structures C4.2.1 General a) Concrete mix shall be minimum 25 MPa at 28 days unless shown to be a higher strength on the specific drawings. b) For manholes the concrete haunching and encasement to pipe penetrations shall be from 25MPa grade concrete and shall be formed such that the inside face follows the original inside line of the manhole. c) Wastewater manhole benching shall be cast and troweled to shape, sloping towards the channel at minimum 1:12. The troweled surface shall be smoothed to U2 finish. Plastering over the concrete finish is not accepted.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 53 of 92 C4.2.1 Foundation The structure shall be founded on a firm and stable base, with site concrete as required, to provide a clean working surface for construction of the manhole. C4.2.2 Roof slab, lids and access a) All lids shall support HN-HO-72 loading. Access holes and other entry points shall be cast into the slab, not cut. b) The lids shall be fixed to the slab as shown in the standard drawings. c) Person accessible entries shall have a minimum clear access of 600mm diameter. Entries or other openings where a person can fall into a pit or chamber with the access lid removed, shall be fitted with an accepted safety grille. d) Step rungs or ladders shall be as shown on the drawings and manufactured from an accepted material to the Watercare material supply standard. Refer to Watercare’s mechanical construction standard for construction and installation requirements. C4.2.3 Infiltration performance The sealing between joints shall be with an acceptable material providing 100 year performance and installed to the manufacturer’s requirements. The sealing material shall meet the minimum infiltration test performance criteria applicable to the installation circumstances. C4.2.4 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Set-out Line and level in accordance with specific drawings N/A Required N/A 2 Foundation Inspected, sound/firm N/A Required As specified 3 Concrete Records: Min 25 MPa or higher as specified Required Required Review document 4 Penetrations All cast in place N/A Required Required 5 Vertical Survey Required Required N/A 6 Infiltration Applicable test per Section 10.5.2 Required Required Required 7 Roof slab/Lid HN-HO-72 certified (where constructed in road-way) Required Required Review document 8 Access lid Appropriate load class fitted Required Required Required Sign-off C4.4 Shotcreting C4.4.1 General Concrete shall comply with the requirements of Section C4.1 of this standard. Shotcrete shall be applied using the wet mix process. C4.4.2 Preparation and trial a) Shotcrete specimens shall be sampled and tested for compliance prior to construction. b) Remove all unsound material before applying shotcrete. Chip or scarify any area to be repaired to remove offsets without suitable reinforcement. Taper the edges to remove square shoulders at the perimeter of a cavity. Remove all loose material from areas receiving shotcrete. c) Wet the surface until it is damp, but without visible free water. Do not place shotcrete on frozen surfaces. d) Sandblast existing surfaces that do not require chipping to remove paint, oil, grease, and other contaminants and provide a roughened surface for bonding.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 54 of 92 C4.4.3 Placement of shotcrete a) Shotcrete shall only be undertaken by experienced, specialised persons able to demonstrate work experience of a similar type to the work being undertaken. b) Control thickness, method of support, air pressure, and/or water content of shotcrete to preclude sagging or sloughing off. Discontinue shotcreting and provide suitable means to screen the nozzle stream if wind or air currents cause separation of the nozzle stream during placement. c) Broom or scarify the surface of freshly placed shotcrete to which, after hardening, additional layers of shotcrete are to be bonded. Dampen surface just prior to application of succeeding layers. d) Commence by filling all corners and any area where rebound cannot escape or be blown free. Complete the corners between the web and the flanges of structural steel before application to the flat areas. e) Provide a supply of clean, dry air adequate for maintaining sufficient nozzle velocity for all parts of the work, and if required, for simultaneous operation of a suitable blowpipe for clearing away rebound. f) Hold the nozzle at such distance and angle to place shotcrete behind reinforcement before any material is allowed to accumulate on the face. Do not place shotcrete through more than one layer of reinforcing steel rods or mesh in one application unless the steel is properly encased, as demonstrated by pre- construction tests. g) Test to determine if any voids or sand pockets have developed around or behind reinforcement by probing with a pointed tool after the shotcrete has achieved its initial set. h) Use adequate ground wires or other accepted means to establish the thickness, surface planes, and finish lines of the shotcrete. Maintain specified tolerances by keeping ground wires secure and taut. C4.4.4 Finishing a) Provide natural gun finish unless otherwise specified. Avoid trowelling thin sections of shotcrete unless both trowelling and the start of moisture curing take place within a short time after placement. b) Do not remove high spots until the shotcrete is stiff enough to withstand pull of the cutting device. C4.4 5 Joints a) Construct joints as indicated in the specific drawings. Unless otherwise shown, construction joints are to be tapered to a shallow edge from about 25 mm thick. b) If the joint will be subjected to compressive stress, use non-tapered joints and take special care to avoid or remove tapped rebound at the joint. c) Make construction joints perpendicular to the main reinforcement. C4.4.6 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Experienced operator Demonstrated to be suitable for task Required Required N/A 2 Trial 5 samples tested per test panel at 7 days and 28 days. NATA/IANZ laboratory results complying with NZS 3109 Required Required Review document 3 Site preparation Inspected to be clean , cleared of debris, loose soil, sandblasted etc. N/A Required Required 4 Contact surfaces dampened N/A Required Required 5 Placement Ground wires in place/similar to gauge thickness N/A Required As specified 6 Probe for voids N/A Required As specified 7 Joints Per drawings N/A Required Required 8 Testing Test results of cores comply (NATA/IANZ lab tested, NZS3109) Required Required Review document 9 Ultrasonic/impact hammer test of finished area - no voids and thickness meeting as specified. Required Required As specified Sign-off
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 55 of 92 C4.5 Formwork a) All formwork design shall be the responsibility of the contractor. Formwork of a structural nature shall be certified by a Chartered Professional Engineer registered with CPEC. b) Formwork shall provide adequate access to perform compaction and be accurately shaped to position, level, finish and dimensions. Joints shall be designed and constructed to withstand the compaction, vibration and loadings imposed during construction and curing. c) The formwork materials shall not absorb moisture and not allowed to bond with the concrete. A non- stain material coating shall be used for surfaces exposed to view. The form-coating material shall not interfere with subsequent bonding to the casting when this is required. d) Formwork bolts shall be allowed for extraction without causing damage to the surrounding concrete. Tie bolt holes shall be treated as type B construction joints for 40mm down the hole and rammed with dry pack mortar or an approved equivalent within two days of formwork removal. The minimum cover to embedded tie bolts shall be 50 mm from the finished concrete surface. C4.6 Concrete defect repairs a) This section applies to new concrete constructed as part of the works that has been inspected and found to be defective. b) Repairs shall only be made that are certifiable and meet the performance requirement and minimum asset life. Other defects shall be completely removed and replaced. c) All non-conforming areas shall be identified in a repair methodology that considers repair material, performance, safety and testing (strength test by NATA/IANZ laboratory) for acceptance by Watercare. d) The area for repair shall be prepared using percussive power tools that will remove all loose, cracked or softened material to leave a clean surface of uncompromised aggregate and concrete. The area shall be free from oils or other contaminating deposits. C4.6.1 Patch repairs a) Defects shall be cut out in straight lines at least 10mm deep. The areas shall be soaked before applying repair material to prevent rapid moisture loss to the adjacent concrete. b) The patch repair material shall be a suitable structural grade modified cementitious mortar, compatible with the existing surface and be crack preventative. In deeper sections the repair material shall be built up in layers to prevent slumping, or as otherwise directed by the manufacturer’s direction. c) The repair shall match the surrounding profile, colour and texture. C4.6.2 Crack repairs Cracks shall be repaired by an accepted structural epoxy injection in a continuous operation. The epoxy shall completely fill the crack to restore the strength of the section. C4.6.3 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Concrete defects Finished concrete inspected for defects by structural engineer N/A Required As specified 2 Methodology Conformed to performance requirements Required Required Required 3 Surface repair Surface inspected - clean and free of loose debris or contaminants N/A Required As specified 4 Product Accepted for compliance with performance requirements of concrete Required Required Required 5 Repair test Accepted methodology. Strength test by NATA/IANZ laboratory Required Required Review document 6 Certification Producer statements Required Required Required Sign-off
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 56 of 92 C4.7 Rehabilitation of wastewater pipe and structures with cement mortar C4.7.1 General The cement mortar lining shall be accepted corrosion resistant calcium aluminate cement. Any fittings or connection attached to the structure or pipe shall be prevented from blocking, and where able will be hand finished. C4.7.2 Surface preparation a) Concrete surfaces shall be cleaned without causing damage to the existing concrete or concrete lining. The preparation shall remove all: • Grease, fat, oils, slime deposits, laitance. • Corrosion products, loose or corroded mortar. • Previously applied coatings. • Any substance that could affect the bonding strength. b) Any bacteria formation after cleaning shall be removed and treated before the mortar application commences. C4.7.3 Mortar application a) Mortar thickness shall be a minimum of 25mm with maximum ±1.5mm variance, and allowed to cure according to the manufacturer’s recommendation. b) The mortar repair shall be allowed a minimum of 72 hours curing time or sooner as allowed by the accepted product. c) Application shall be in layers as recommended by the product supplier to prevent slumping. d) Pipe lining shall be machine applied. Any hand reinstatements shall be limited to small patch repairs and be made be within 24 hours of the machine application. e) Where the machine accessed the pipe, the machine application shall be fully completed with the machine, cut back 75mm and hand rendered. f) Steel pipe that has been cut open shall be prepared with an acceptable high heat resistant mortar that will seal the mortar behind the weld. g) The mortar surface finish shall be equivalent to U3. C4.7.4 Record keeping The record form shall be completed per component that is being rehabilitated or in the case of pipelines between access points, batches or shifts. Structure information Contractor Installation site identifier Asset ID Address Access location Grout mix Date Time Manufacturer batch number Mix composition Mix Volume C4.7.5 QA/QC Template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 CCTV - start Records evaluated against design stage records Required Required Required 2 Pipe cleaning HB84-2006 guidelines N/A Required As specified
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 57 of 92 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 3 Product compliance Accepted material Required Required Required 4 Mortar application records Min. 25mm, ±1.5mm. Required Required Required 5 Testing Samples to AS 1012 part 24, tensile bond strength Required Required Review document 6 CCTV – final U3 finish. No visible slumping or cracking Required Required Required Sign-off C5. Painting C5.1 General a) This standard applies to the in-situ application of as per the materials standard for painting of general civil and mechanical infrastructure. b) The appropriate painting system shall be applied for the structure function and location. All preparation including blasting, priming and system application shall be in accordance with the product supplier’s direction. c) Power tool cleaning shall not be used as an alternative to blast cleaning except for those surfaces, which because of their location, cannot be open blasted. d) Coatings shall only be applied to clean and dry surfaces and only in dry weather, except where coating is carried out indoors. Any coating damaged by heat, rain, moisture, or condensation shall be removed and a fresh coating applied. e) Painting shall not continue if any of the following conditions apply, unless otherwise restricted by the manufacturer: • The surface temperature is below 8o C or exceeds 30o C • The surface temperature drops to below 3o C above the ambient dew point • The relative humidity exceeds 85% • Inclement weather such as rain, snow, fog, frost, mist or dust • Excessive high winds f) The above moisture restrictions do not apply to paint applications in damp conditions. Note – Watercare has currently standardised on Altex coatings for its pipework, equipment and in aggressive environments such as wetwells and Belzona for abrasive pump headers. The full manufacturer specifications for the product range and selection for Watercare’s infrastructure is available in the materials standard. C5.2 Painting of pipes, equipment and structures The general colour coding and coating specifications for Watercare pipes and equipment is listed in the following tables. For application details refer to the coating systems in the material supply standard. Table C5.2‐1 Water reticulation services colours Location PBS 5252 Colour No. Colour (Resene) Pipe bridges 12 B 29 Karaka Green Pipework and valves in chambers 16 A07 Boulder Pump station and reservoir pipework 18 E 53 Bahama Blue Pumps 00 A 09 Haze Grey Inlet valves at reservoirs and pump stations 14 E 56 Fun Green Outlet valves at reservoirs and pump stations 04 E 53 Guardsman Red Check valves at reservoirs and pump stations 06 D 45 Peru Tan
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 58 of 92 Location PBS 5252 Colour No. Colour (Resene) Valves with actuators and control valves at reservoirs and pump stations 06 D 45 Peru Tan Scour valves at reservoirs and pump stations 08 A 14 Bokara Grey (this is black) Safety handrails 08 E 53 Yellow Monorail beams at reservoirs and pump stations 12 D 43 Trendy Green Pump room, motor room, control room floor 00 A 09 Haze Grey Table C5.2-2 Wastewater reticulation services colours Location PBS 5252 Colour No. Colour (Resene) Pipe bridges 12 B 29 Karaka Green Pipework and valves in chambers 00 A 09 Haze Grey Pump station pipework and valves 00 A 09 Haze Grey Pumps in drywell 00 A 09 Haze Grey Electric motors As Supplied Ventilation fans and ducting Match walls Safety handrails 08 E 53 Yellow Gantry cranes and monorail beams 08 E 53 Yellow Pump room, motor room, control room floor 00 A 09 Haze Grey C5.2.1 External pipe painting a) When pipes are to be painted externally, the prime coat shall be carried around the ends of the pipe and into the socket, to the edge of the concrete lining or to the setback distance Ec (for EC value see spiral weld steel pipe supply standard). b) Where pipes are to be wrapped, the prime coat shall be applied from the wrapping, around the ends of the pipe and into the socket, to the edge of the concrete lining or to the setback distance Ec. C5.2.2 Internal pipe painting a) Pipe assemblies that are not concrete lined shall be painted in accordance with the manufacturer’s requirements. The paint lining shall extend to the setback dimension Ec (for Ec value see spiral weld steel pipe supply standard) from the end of the pipe socket, and the remainder of the socket shall have a primer coat only. b) For concrete lined pipe the paint shall overlap the mortar lining on spool sections by 50mm. C) Painting shall be completed following all welding and before bolting up of valve assemblies. The mating surfaces of flanges shall remain unpainted. Repair mortar used at flanges to fair off a concrete lining against a flange shall not be applied over painted surfaces. C5.2.3 Painting of buildings a) While materials may be obtained from different makers, for any individual paint system, only one maker's products shall be used. This restriction shall not apply to alkyd enamel top coats used for architectural or decorative purposes only. b) Unless otherwise specified, the paint manufacturer’s instructions for the application of any paint system shall take precedence over any general requirement in this section. c) Zinc rich paint shall consist of zinc dust pigment carried in a suitable medium such that on drying, the film shall contain more than 95% of zinc powder. The zinc powder shall contain more than 97.5% of pure zinc.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 59 of 92 d) The painting applications building and its associated components shall be as per the following tables below. Table C5.2.3-1 Paint system, preparation and application Note - See tables C5.2.3-2/3 for codes used in this table for preparation and paint systems. The colour codes correspond to BS5252. Item Preparation Paint system Colour BS 5252 a) Aluminium hatch covers Unpainted b) Cast iron pipework and valves inside control building Refer to the material supply standard 12D43 c) Cast iron pipework in wet well Refer to the material supply standard Light grey d) Copper pipework T9 S8 To match background e) Downpipes, lifting hatch support rails T6 S9 10B21 (to match roof) f) Floor (Concrete) of Switchboard Room TG-2010-108820 (see note) Light grey g) Formica toilet partition, PVC waste pipes Unpainted h) Galvanised steel handrails and ladders T6/T7 S9 12D43 i) Galvanised Steel, fittings and brackets inside valve chamber T6/T7 S9 12D43 j) Gutters - Coloursteel Lichen k) Interior wooden doors and frames T4 S17 Clear l) Roof - upper surface - Coloursteel Lichen m) Roof underside - fibrous plaster T5 S7 White n) Stainless steelwork in wet well or storage tank Unpainted o) Structural Steel, Monorails etc. TG-2010-108802 (see note) 22B19 p) Walls of building & valve chambers, concrete, interior to be unpainted – if nominated as being painted in the particular clauses, use - T1 S1 10B15 q) Walls of building, concrete masonry, Exterior, T1 S2 10A03 r) Walls of building, concrete, exterior to be unpainted, - if nominates as being painted in the particular clauses, use - T1 S2 10A03 s) Walls of building, plasterboard, interior T15 S18 10B15 t) Walls, concrete masonry, retaining or free standing walls, exterior locations Unpainted u) Walls, concrete, interior and ceiling of wet well and access platform T1 S14 White v) Woodwork - roof beams - - Unpainted
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 60 of 92 Table C5.2.3-2 Preparation codes for table C5.2.3-1 Treatment Surface and preparation T.1 Concrete and concrete masonry Remove all fins, mortar splashes, efflorescence, and foreign coatings, brush down to remove dust and loose material. Fill all cavities and depressions with an approved filler. Where form oil has been used, scrub down with detergent and water and finish rinse with clear water to remove all detergent. Prime with two coats of masonry sealer/filler; waterproofing compound. T.2 As T1, but dampen before primer coat. T.3 Woodwork Remove all dirt, grease, oil, and crayon marks by sanding as necessary. Plug all knot holes and seal all resinous areas and knots with one coat primer. After priming and fixing, stop nail holes, surface indentations and all imperfections, rub down and brush off. T.4 Remove all dirt grease, oil, crayon marks by sanding as necessary. Plug all knot holes with plastic wood filler. T.5 Fibrous plaster Prepare in accordance with AS/NZS2311 T.6 New zinc, galvanised and zinc spray surfaces Wash with white spirit or purpose-made solvents. T.7 Weathered zinc, galvanised and zinc spray surfaces Remove all salt deposits, dust dirt etc. and scrub with stiff bristle brush, and wash with clean water. T.8 Aluminium mill finish, lead, copper Wash with white spirit and either roughen with abrasive paper or treat with etch primer. T.9 Roughen with abrasive paper and wash with white spirit or mineral turpentine. T.10 Structural steel, iron and welds Remove rust, mill scale and slag to dull brown or grey finish. Normal procedures in combination or separately as necessary - wire brushing, scraping, hammering, flame cleaning, grinding, sanding, etching and/or use of suitable solvent cleaners. Thoroughly rinse after pickling procedure. T.11 Blast clean to Swedish Standard SIS 05 5900 class Sa 2½. Prior to blasting welds shall be ground to remove sharp edges, weld-splatter and other sharp edges. T.12 Flame clean and/or grind or use chemical stripper to remove all primer and mill oil. T.13 Painted steel and cast iron (factory applied) Remove coal tar coating with solvent and clean down.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 61 of 92 Treatment Surface and preparation T.14 Any damaged areas to be wire brushed or sanded to give a clean surface. Wash with white spirit or mineral turpentine. T15 Gypsum Plasterboard Prepare in accordance with AS/NZS2311 T.16 Steel with zinc rich epoxy primer (factory applied) Any damaged areas to be wire brushed or sanded to give a clean surface and recoated with zinc rich epoxy primer. T.17 Existing painted surfaces Clean all areas of grease, oil, dirt and dust. Sand to a matt finish. Table C5.2.3-3 Paint system codes for table C5.2.3-1 System No Paint system S.1 Masonry sealer/filler, two coats 100% acrylic high gloss. S.2 Masonry sealer/filler, epoxy top coat to a dry film thickness of 100 microns. S.3 Masonry sealer/filler, alkyd undercoat, alkyd high gloss enamel. S.4 Exterior sealer, alkyd undercoat, alkyd high gloss enamel. S.5 Alkyd undercoat, alkyd high gloss enamel. S.6 Alkyd primer, alkyd undercoat, alkyd high gloss enamel. S.7 Sealer/filler, alkyd undercoat, alkyd high gloss enamel. S.8 Zinc rich paint, zinc chromate primer, alkyd high gloss enamel. S.9 Zinc rich touch-up, zinc chromate primer or etch primer, alkyd high gloss enamel. S.10 Touch-up shop primer, metal undercoat, alkyd high gloss enamel. S.11 Zinc rich epoxy primer (factory applied), touch-up zinc rich epoxy primer, two coats high build epoxy. S.12 Zinc rich epoxy primer (factory applied), touch-up zinc rich epoxy primer, vinyl etch primer or epoxy primer, alkyd high gloss enamel. S.13 Touch-up shop primer, metal undercoat, high build epoxy. S.14 Epoxy primer, two coats of epoxy high gloss. S.17 Two coats clear varnish. S.18 Two coats 100% acrylic semi-gloss. Paint and surface finish for the motor control panel covered in the specification for Manufacture of Switchboard.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 62 of 92 C5.3 Field touch-up painting a) Touch-up painting will be required at field welds, bolt assemblies, primed-only surfaces, and to areas damaged during transportation, handling, storage, or construction. b) Before touch-up painting: • All damaged paint film shall be removed • All grease, oil, dirt or other foreign matter shall be removed • All edges of sound paint shall be feathered by sanding or grinding • Existing gloss paint surfaces shall be sanded or abraded for bond (an exception can apply to some urethane topcoats, to be confirmed with the paint manufacturer) c) Bare spots that have exposed the prime coat but not the base material shall have one or two finish coats applied to regain the specified film thickness. d) If the base material or substrate has been exposed the area shall be cleaned down to the base metal in accordance with either SSPC SP-3 or SSPC SP-11, and the area touched up as specified by the manufacturer’s specification. e) Where corrosion has occurred in the base metal due to the damage to the paint system, the area shall be re-cleaned to the original surface preparation requirement and the full specified coating system applied. C5.4 Protection of work and adjacent equipment a) Before commencing any painting work, all exposed hardware and fittings that might be damaged by paint shall be removed and stored ready for re-fixing in the original condition upon completion of the work. b) Any items not to be blasted or painted (e.g. machined faces, instruments, threaded surfaces, tags, and name plates) are to be adequately masked to protect from blasting damage or overspray. Any overspray or over blast is to be promptly made good. c) Clamps or sorting hooks shall be used for handling steel after the prime coat has been applied. Wire rope or chain chokers shall not be used. d) After the finish coat has been applied, only nylon ropes or rubber covered slings may be used for handling steel during loading, unloading or erection. e) The Contractor shall rectify any damaged coating. C5.5 Valve box cover paint colours Service component Location Colour Hydrant Water retail networks Yellow Valves (Peat valves, shut-off valves, air valves Water retail networks White Water transmission Blue Water meter boxes Water retail networks Black Special controlled zone isolation valve (normally shut position) Water retail networks Red Pressure boundary kits and valves on rising mains Wastewater retail networks Red Grey water (all component) Grey water Purple C5.6 Painting equipment a) Equipment shall comply with the recommendations of the coatings manufacturer. Unless otherwise specified: • Application for coatings is by airless spray or air-assisted airless spray • Use heavy duty conventional spray equipment or high-volume low-pressure (HVLP) equipment at the correct air and fluid pressures to give correct application • Brush application is restricted to those areas which cannot be spray-coated due to difficult access or complex shape • Non-sparking drives are mandatory where fume concentrations have the potential to exceed half of the lower explosive limit b) Air supply shall be fit for the purpose, free from contamination and of sufficient pressure and volume for the job. c) Regulators and gauges shall be provided for the air supply to the pump and pressure pot and the air supply lines shall be fitted with efficient oil and moisture traps.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 63 of 92 C5.7 QA/QC template Paint inspection record Project: Engineer witness: Contractor: Sign-off Inspector/supervisor: Sign-off Coating specification reference: Items inspected Substrate Coat 1 Coat 2 Coat 3 Coat 4 Date/Time % RH Climate Air Temp Data Dew Point Surface Temp Date/Time Surface Cleanliness Preparation Profile Type Paint/ Date/Time Application Batch Number Mixing Thinning Date/Time W.F.T Number Min Coating D.F.T Max Inspection Average Std Dev Holiday Appearance Comments:
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 64 of 92 C6. Demolition and abandonment C6.1 General Demolition includes the removal of structures or facilities as well as the safe abandonment of below ground structures and pipelines. Work shall be conducted efficiently and safe in a manner that prevents damage to infrastructure and the environment. C6.2 Existing work and damage a) The structure to be demolished shall be inspected and the demolition method produced. Where available the contractor shall study the structure’s drawings and specifications. b) Where underground pipelines and structures are to be abandoned and filled, the inspection shall identify defects that may compromise the filling activity. C6.3 Protection of people, property and environment a) . A pre-condition survey shall be done on surrounding infrastructure and utility locations identified before any demolition activity commences. b) Damage to other structures shall be repaired by the contractor to the original condition c) Explosives shall not be used for demolition works. d) Adequate support and shielding shall be provided to protect existing structures, the environment, the public and any other person. e) Abandonment of structures and the infill material to render the abandoned structure safe shall unless otherwise specified, consider the following requirements, to be accepted by Watercare: • Short and long term environmental affect i.e. current service condition (damage, joint type), delayed deterioration of the host, etc. • Risk of future collapse • Risk of future development over an abandoned structure i.e. housing • Location of the service i.e. coastal marine, underground aquifers, fissures or underground drains, ground conditions, location to streams, service depth and structural loading • End cap and filling point design as well as tie-off requirements at completion that is appropriate to the product being used • Product shrinkage and the risk impact it will have on the structure in its location on either failure or leaching C6.4 Removal of material All material and other rubbish generated by demolition activities shall be removed to an appropriate tip site. C6.5 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Preparation Facility plans and specifications Required Required N/A 2 Utility service plans and mark-outs Required Required N/A 3 Pre-condition survey Required Required N/A 4 Site management Demolition plan Required Required Required 5 Abandonment Methodology and product approval Required Required Required 6 Material removal Appropriate tip site dockets Required Required As specified Sign-off C7. Masonry C7.1 Workmanship Registered masons or tradespeople under the direct supervision of a registered mason shall be used for masonry construction. A registered mason shall be on site at all times during masonry construction work.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 65 of 92 Masonry to carry temporary loading shall be certified by a chartered structural engineer. The certification shall be forwarded to Watercare for acceptance. C7.2 Materials handling and block types a) Damaged blocks shall not be used. b) Unless shown otherwise blocks for 200 walls shall be open ended web bond beam type blocks type 20.16 except at wall ends which shall be lintel blocks type 20.12 alternating with type 20.13. c) Use inverted series 20.16 for the first course. d) Where shown on architectural drawings, use rebated blocks type 20.11 and 20.13 for window jambs and where detailed. e) For window heads use type 20.08 sill blocks where detailed. f) Type 20.16 blocks shall not be positioned with webs adjacent to each other. C7.3 Laying of masonry a) Cutting of blocks shall be avoided as far as practicable. Particular care shall be taken in cutting blocks for mitre joints to ensure straight neat edges are achieved and even 10mm mortar joints obtained. b) Unless specified otherwise, lay all blocks in running bond. Blocks shall be laid true to line, plumb and level with the thicker end of the shell up in mortar courses. c) All joints shall be in complete contact with mortar after bedding in. Masonry in construction shall be stabilised as necessary without compromise to the structural integrity to prevent any lateral force that may topple the construction. d) All joints shall be tooled appropriately where exposed to view forming sharp, clean lines and compact right joints. Unless specified otherwise all joints shall be formed to a concave shape using a proprietary tool. e) After laying, the mortar shall be prevented from drying too rapidly in hot dry weather by applying a very light fog spray several times during the first twenty-four hours. f) `Knock-ins' shall only be used on approval. The knock-in shells shall be placed so as not to protrude into the flue to be grouted and yet prevent any grout loss into flues to be unfilled. g) Allow for building in all bolts, fixings, ties, joinery pipes, flashings and all other embedded metal work, hardware and all conduited, boxed and wired services as may be required by this and other trades. Only the block layer shall carry out whatever cutting is necessary and all patching and making good required after the other trades have completed their work. h) In exposed blockwork, cut-outs shall be symmetrically placed in the block. Cut-outs shall not be visible after the fixing of cover plates. i) The block layer shall ensure that positions of reinforcement starters, rebates etc. are located accurately to suit the blockwork. j) The starter bars should be checked for position before laying the first course of blockwork. k) If the starter bars are incorrect then work shall only proceed with written approval. Double cranking of starter bars to align with continuing steel is not acceptable. C7.4 Clean-out ports a) Provide clean-out ports in the bottom course of all high-lift and other walls where cleaning of mortar droppings and debris is not possible by other acceptable means. b) Use inverted series 20.16 blocks for the first course to each grout lift. Ports shall be a minimum of 200mm high by 100mm wide. c) Locate ports at each vertical reinforcing bar position on the wall side, with least visibility. Remove full block face shell and after grouting replace to align with wall face and to form even joints to match existing. C7.5 Control joints a) Reinforce and grout vertical cores to both sides of joints. Control joints shall be sealed with 10mm x 10mm minimum section of grey colour "Thioflex" or approved equivalent, applied to the clean dry joints according to the supplier's instruction. Before caulking, rake out to 20mm depth. b) The sealant shall be applied full height both sides of control joints and using masking tape both sides of joints to prevent marking of exposed walls. Remove the tape after the surface has become firm. Shape the sealant to match mortar joints.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 66 of 92 C7.6 Reinforcement a) Reinforcement shall be as shown on the specific drawings except that links, stirrups and ties shall not be less than Grade 300 plain round bars. b) All masonry cells shall be solid grout filled. Compaction shall be by rodding or vibration. C7.7 Filling cores All grout spaces shall be cleaned out and the mortar joints reached sufficient strength before commencing with grout pour. C7.8 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Qualification Registered mason(s) Required Required Required 2 Material inspection Block without defects/unbroken N/A Required As specified 3 Joints 10mm even mitre N/A Required As specified 4 Reinforcing As per drawings and min Grade 300 for links, stirrups and ties. N/A Required Required 5 Test mortar Min. 3x successive samples at start (min 1 per day). NZS 4210 Appendix 2 Required Required N/A 6 Grout spaces cleaned Visual inspection N/A Required As specified 7 All cores filled Visual inspection N/A Required As specified Sign-off C8. Plumbing C8.1 General a) This section covers general domestic or similar type installations. Work shall be carried out to meet the requirements of the Building Regulations 1992 (SR 1992/150) – Section 1. Work shall be carried out by persons authorised under the Plumber, Gasfitters and Drainlayers Act. b) Preparatory work including supporting structure, framing and sleeved or formed openings shall be inspected before work commences and any defects immediately made good. c) Galvanised steel pipe buried in the ground or in concrete shall have oil and grease removed by solvent washing and then wrapped with an accepted corrosion protection tape. Tape width shall be applied to give 50% overlap. d) Runs shall be to even grades and fixed with collars and supports of appropriate materials to suit the pipes. Supports shall be regularly spaced to provide full support and prevent movement and deflection. All bends shall be sweep bends or easy right angle bends. Elbows shall not be used. At ends of horizontal pipe runs and at changes of direction of waste pipes suitable inspection and clearing points shall be included as required by regulations. e) Exposed wastes and vents shall be fixed 40mm clear of wall surface using stand-off brackets. Pipes and vents passing through walls and roofs shall be neatly and completely weathered. Wrap pipes with an accepted protective tape, where passing through concrete slabs or walls. Where possible all pipework shall be concealed in walls, ceilings, floors, and ducts or as otherwise shown on the specific drawings. f) To prevent electrolytic action, dissimilar materials shall be separated by suitable inert materials as interlayers, sleeves or as applied impervious coatings. g) Fixings including nails, screws and bolts shall be fully compatible with and/or of similar materials as the work being fixed and resistant to corrosion. h) After completing leakage tests the system shall be flushed with potable water from the highest point at minimum 1m/s flow velocity until the water is running clear.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 67 of 92 C8.2 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Qualifications Registered as authorised Required Required N/A 2 Pipework inspected Pipe wrapping Dissimilar materials isolated Directional change with sweep bends N/A Required Required 3 Test Gravity – leakage test for non- pressurised pipes. Water – pressure tested for plumbing works (see section 10). No leaks Required Required As specified 4 System flushed Water running clear N/A Required As specified 5 Certificate of Code Compliance As per the Building Act 2004. Required Required Required Sign-off C9. Carpentry C9.1 Workmanship a) All timber shall be worked and cut to a proper contact fit in accordance with best trade practice. b) All connections shall be accurately made and properly executed to provide sound connections for the class of work required. In exposed work all nails shall be well punched and screws adequately countersunk to allow for finishing with stopping work. c) All framing shall be fixed true to line, plumb and square and/or to the plan profiles. The maximum tolerance from plane to plan profiles shall be 6 mm in 3 m measured from a straight edge or template. d) Joinery fittings shall be shop manufactured. All work shall be free of defects. All exposed exterior work shall be machine finished. All hammer marks shall be removed. All timber exposed to view shall be dressed and sanded smooth. e) All floors shall be sanded to a smooth finish to line level and profile fully compatible with the finish to be applied. f) The checking and cutting of timbers and framing shall be reduced to a minimum and checking shall be replaced with bored holes where possible. g) The checking of plates and studs shall be less than 15 mm for 75 mm members and 25 mm for 100 mm members. Holes drilled through the centres of members in lieu of checking as above may be to 25 mm diameter and 35 mm diameter respectively. h) Beams and joists shall not be notched or holed on their edges at any point closer than 600 mm to the end supports. Holes shall be drilled only along the neutral axis. Holes or notches shall not exceed 1/5th of the depth of the beam or 30 mm diameter or edge dimensions whichever is the lesser. C9.2 Fasteners and fixings a) Electro plated fixings are not permitted. b) Screws shall be of steel unless otherwise specified and of suitable gauge and length to ensure adequate fixing. c) Fasteners or fixings where exposed to the weather, or in damp conditions, or through cedar or redwood shall be galvanised steel, brass, copper or stainless steel. d) Finishing nails shall be suitable for the class of materials to be fixed. C9.3 Timber treatment a) Unless otherwise specified, the minimum standard of treatment shall be grade H3.1 in accordance with NZS 3602. b) Fixing to concrete work shall be made by screwing; nailing or dovetailing using H4 classification treated pine or approved plastic grounds. c) Machine stress graded timber to MSG10 in accordance with AS/NZS 1748 shall be used for all roof and floor framing.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 68 of 92 C9.4 Timber sizes a) All framing timbers unless specified otherwise shall be machine gauged four sides. Dressed timbers shall be to the finished sizes shown on the specific drawings. b) Other timbers shall not be dressed or thicknessed or cut down by more than 10 mm below the nominal size. C9.5 Framing a) Linings shall not be fixed until the framing and preparatory work has been checked to ensure proper alignment. b) Linings shall be fixed true to line, plumb and square and straight and flat to plan profile. c) The maximum tolerance from plane to plan profile shall be as follows: • Gradual Irregularities: 6 mm in 3m measured from a straight edge or template • Abrupt Irregularities are not permitted C9.6 Moisture content a) In addition to the requirements of NZS 3602, all finishing timbers and strapping for linings shall be dried to a moisture content between 8% and 13% and shall be kept dry at all times. Timber showing signs of faulty or excessive kiln drying shall be rejected. b) Framing timbers shall be reasonably dry when erected and shall have dried to moisture content of between 16% and 20% before internal linings are applied. Framing timbers exposed to view shall be dried to less than 16% moisture content. Finishing timbers in areas shown to be air-conditioned or to be heated by a central plant shall be dried to less than 10% moisture content. c) Moisture contents specified above shall be based on oven-dry weight. C9.7 Material handling a) Framing timbers stored on the site shall remain bundled until required for use and protected from moisture, contamination, and excessive sun exposure. b) All joinery and dressed timbers shall be completely protected from the weather, contamination, and damage for the duration of the work. C9.8 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Material storage Dry, not exposed to elements N/A Required As specified 2 Timber type H3.1 to NZS3602 (H4 where fixed to concrete); MSG10 to AS/NZS1748 for floor and roof framing Required Required As specified 3 Fasteners No plated. Required. Required As specified 4 Measure wood moisture content General 16%-20% Heated functional area <10% Required Required Required 5 Inspect framing Irregularities less than 6mm in 3m Framing fixed to concrete H4 grade N/A Required As specified 6 Cutting and jointing Within limits of workmanship requirements. N/A Required As specified Sign-off C10. Metal roofing C10.1 General a) All material shall be new and free from defects, damage or dirt. b) The type, class, gauge and profile shall be as per the specific drawings. c) Underlay shall be breather type and waterproof.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 69 of 92 d) Nails, screws and fastenings shall be in accordance with the roofing manufacturer’s specifications and comply with the relevant aspects of NZS 3604. e) Accessories, capping, flashings and fixings shall match the metal roof type and be in accordance with the roofing manufacturer’s requirements. C10.2 Execution of work a) Roofing and accessories shall be stacked on clean, level areas of the site and protected from damage and weather until ready to fix in place. b) The roof structure shall not be overloaded when roofing materials are placed on the roof area prior to installation. c) All installation shall be undertaken by commercial installers, certified by the roofing material manufacturer or other approved experienced and competent roofers familiar with the roofing material to be installed. d) Clean soft-soled shoes shall be worn by the roofing installers whilst walking on coated roof surfaces. e) Installation shall be in accordance with the requirements in the NZ Metal Roofing Manufacturers Inc: “NZ metal roofing and wall cladding code of practice”. C10.3 Joints a) All fixings shall be made strictly to the manufacturer's recommendations and/or as shown on the plans or specified in the schedule. b) Any welding shall be carried out by specialist welders experienced in the class of work required. c) Expansion joints shall provide full weather tight laps in addition to allowing temperature movements. The contractor shall allow for all special fittings, gaskets and fixing to expansion joints. d) Suitable barriers between dissimilar metals shall be provided to prevent electrolytic action and corrosion as recommended by the manufacturer. C10.4 Capping, flashings and other hardware The contractor shall provide and fix all the necessary flashings and over-flashings to completely weatherproof the roofing. C10.5 Damage and performance a) Visibly bent, dented or heavily scratched roof sheeting shall be removed and replaced. Scratches to the colour coat that have not penetrated to the base metal and is visible to less than 1% of the sheet surface shall be left as is. b) The contractor shall provide a written guarantee of water tightness for a period of five years from the completion of the work. C10.5 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Material per drawings Gauge as specified. Material certified to NZS 3604 N/A Required As specified 2 Material inspected for defects No bends, no dents & scratches <1% of total area. N/A Required As specified 3 Installer certified Required Required N/A 4 Joints inspected Dissimilar material isolated, weather tight N/A Required As specified 5 Guarantee provided 5 year certification Required Required N/A Sign-off
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 70 of 92 C11. Polymer-type chambers C11.1 Approved chambers a) Chambers must be approved by Watercare for use with specific limitations on purpose and location suitability. Acceptable chambers are listed in the Watercare Material supply Standard. b) Where integral bases are not supplied with chambers, a concrete chamber floor shall be installed in accordance with section C4.2. c) Where chambers are not supplied with an approved lid, a concrete lid shall be manufactured in accordance with section C4.2. C11.2 Foundation The chamber shall be founded on a firm and stable base, with site concrete as required, to provide a clean working surface for construction of the chamber. C11.3 Penetrations a) Penetrations shall not be cut in areas, or of a size and quantity that may compromise the chamber wall integrity. b) Penetrations shall be cut by hole-saw. c) Penetrations shall be sealed against the pipe with an approved proprietary rubber sealing system. C11.4 Infiltration performance The sealing between all joints shall be with an acceptable material providing 100 year performance and installed to the manufacturer’s requirements. The sealing material shall meet the minimum infiltration test performance criteria applicable to the installation circumstances. C11.5 Backfill Backfill shall be in layers and of material as specified by the product supplier. C11.6 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Set-out Line and level in accordance with specific drawings N/A Required N/A 2 Foundation Inspected, sound/firm N/A Required As specified 3 Penetrations Hole-sawed to size with suitable rubber seal N/A Required Required 4 Vertical Survey Required Required N/A 5 Infiltration Applicable test per Section 10.5.2 Required Required Required 6 Roof slab/Lid HN-HO-72 certified (where constructed in road-way) Required Required Review document 7 Access lid Appropriate load class fitted Required Required Required Sign-off
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 71 of 92 10. Testing This section prescribes the testing requirements for the various civil construction components covered in this standard. 10.1 Roading and development NZ Transport Agency: NZTA M10 Notes, Table N3.1, Design level 1. Standard and Optional tests apply. 10.2 Backfill compaction testing NZS 4402, Test 5.1.2 and 5.1.4. Testing shall be carried out by a NATA/IANZ accredited laboratory. 10.3 Installation of polyethylene pipe a) Pipe out of roundness and eccentricity tests as per dimensional tables in: AS/NZS 4130 Polyethylene (PE) pipes for pressure applications. b) Butt weld test by NATA/IANZ accredited laboratory to ISO 13953. Butt weld test methodology Butt welds shall be shown to be fully ductile by destructive testing. Weld samples shall be clearly marked with identifying marks and with the orientation of the weld in the welding machine. The testing laboratory shall be instructed to report test results with reference to the orientation of the weld in the welding machine. The weld beads shall not be removed for testing. In addition to the weld sample a section of unaffected pipe wall shall also be tested. The following shall be provided in addition to the test report specified by the testing standard: • Report the strength of each butt-weld test piece as a % of the strength of the unaffected pipe wall • A graph of load versus extension for all test pieces plus the specimen of unaffected pipe wall shall be plotted on the same axis – the plot shall record load and extension until there is complete separation of all the test pieces • Clear photographs of showing each test piece in elevation before testing • Clear photographs of the fracture surface of each test piece after testing • Observations and clear photographs showing anything unusual that may affect the test Butt-welds shall be free of visual defects. Unacceptable visual defects include: • Misalignment equal to or greater than 10 % of the pipe wall thickness • The bead is not fully rolled-over and symmetrical • The weld bead is not within the tolerances of POP003 • Pitting or bubbling in the weld bead • Discolouration of the weld bead • Inclusions or other obvious faults Where a butt weld has any of these visual defects it shall be considered unacceptable and shall be cut-out and replaced at the Contractor’s cost. Satisfactory completion of a hydrostatic pressure test shall not constitute acceptance of the butt welds. To be acceptable the butt weld shall: • Have a strength not less than 95% of the strength of the unaffected parent pipe, and • Be fully ductile. c) Electrofusion joint weld test by NATA/IANZ accredited laboratory to ISO 13954 d) Electrofusion saddle weld test by NATA/IANZ accredited laboratory to ISO 13956 e) Extremely thick walled electrofusion assemblies by NATA/IANZ accredited laboratory to ISO 21751
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 72 of 92 Electrofusion joints and fittings test methodology Electrofusion socket assemblies such as couplers and bends removed for destructive testing shall have a minimum of 150 mm of pipe length either side of the socket. Tapping saddle samples for destructive testing shall have a minimum of one diameter of pipe either side of the tapping saddle or tapping tee. Weld samples shall be clearly marked with identifying marks. Electrofusion socket welds shall be free of the following visual defects: • Misalignment • Melt rise indicators not rising, or are unequal • Eruption of melt material past the melt rise indicator • Hand scraping (not allowed) • Depth of peel is less than 0.2mm deep • Mechanical scraping which does not extend past the area covered by the coupler (including area covered during assembly) • Witness marks not evident • Loss of melt material past the cold zone • Element wires extending past the cold zone Where an electrofusion weld has any of these visual defects it shall be considered not acceptable and shall be cut-out and replaced at the Contractor’s cost. Notwithstanding the visual appearance electrofusion welds shall be shown by destructive testing, to fail by ductile rupture of the weld plane. Less than 33% of the total fusion zone may be brittle. 10.4 Steel pipe weld band, socket and spigot joints – Pipe ≥700mm NB Refer to the Mechanical construction standard. 10.5 Pressure and leakage testing This specifies methods of tests and their application to field testing of pipelines and manholes for the purpose of determining acceptability. Field testing includes leak or hydrostatic pressure testing, as appropriate, for pressure and non-pressure pipelines and manholes. Field testing does not replace the test requirements of product standards. 10.5.1 Pipeline testing Note - The type of test shall be selected according to the application of the system and the type of material being tested. A) Non-pressure pipelines – Field leakage testing Leakage testing is used to reveal locations of potential infiltration and exfiltration due to the inclusion of damaged pipes, seals, or incorrectly made joints in the pipeline at the completion of installation. Leakage testing for acceptance of non-pressure pipelines shall be carried out by at least one of the following methods: A-1) Low pressure air testing; or A-2) Hydrostatic testing Note – Air tests provide qualitative data only, as air pressure losses cannot be related directly to water leakage rates. For pipeline test sections installed below the water table and for submarine pipelines, the test pressure used for the hydrostatic test and for the air test, shall be increased to maintain the required differential between internal and external pressure. A pipeline failing to meet the requirements of the air tests may be retested using the hydrostatic test method.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 73 of 92 A-1) Low pressure air test The test length shall be acceptable where the gauged pressure exceeds 18 kPa (or not more than 7 kPa less than the pressure at the start of the test) for the time interval shown in table A-1 after shut-off of the air supply. Table A-1 is based on an air test pressure of 25 kPa in excess of any external hydrostatic pressure due to groundwater and, on this basis air volume losses shall not exceed the greater of: a) A rate of 0.0009 m³/(min x m²) of pipe wall area; and b) A rate of 0.056 m³/min, which is regarded as the lowest detectable individual air leak c) Column 2 and column 3 of table 1 give the times and lengths up to which (b) prevails over (a) Note – For safety reasons air test pressures in excess of 50 kPa should not be applied. Table A-1 – Low pressure air and vacuum tests – Minimum time intervals for 7 kPa pressure change in pipeline DN Minimum time (minutes) Maximum length for minimum time to apply (metres) Test length (metres) 50 100 150 200 250 300 Minimum test duration (minutes) 80 1.5 231 1.5 1.5 1.5 1.5 1.6 2 100 2 185 2 2 2 2 3 3 150 3 123 3 3 3 5 6 7 225 4 82 4 5 8 10 13 15 300 6 62 6 9 14 18 23 28 375 7 49 7 14 22 29 36 43 450 9 41 10 21 31 41 52 62 525 10 35 14 28 42 56 70 84 600 11 31 18 37 55 73 92 110 675 13 27 23 46 70 93 116 139 750 14 25 29 57 86 115 143 172 900 17 21 41 83 124 165 207 248 1000 28 12 51 102 153 204 255 306 1050 20 18.8 56 112 169 225 281 337 1200 23 15 73 147 220 294 367 441 1500 28 12 115 230 344 459 574 689 NOTE – The time interval may be reduced for a proportionate reduction in the allowable pressure drop. Where there is no detectable change in pressure after 1 hour of testing, the section under test shall be deemed acceptable. This table is based on the following equation: T = 1.02DikLq where T = time for a 7 kPa pressure drop, in seconds Di = pipeline internal diameter, in metres q = allowable volume loss in cubic metre/minute/square metre taken as 0.0009 m3/min.m² k = 0.054DL but not less than 1 L = length of test section, in metres. Columns 2 and 3 have been calculated with k = 1.0. The appropriate air or vacuum test/pressure method for pipes larger than DN 750 should be established by reference to the specifier.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 74 of 92 Low pressure air test procedure The procedure shall be as follows: a) Pump in air slowly until a pressure of 25 + 5−0 kPa is reached. Where the pipeline is below the water table this pressure shall be increased to achieve a differential pressure of 25 kPa. In no circumstances should the actual pressure exceed 50 kPa; NOTE – Rapid pressurisation may cause significant air temperature changes, which will affect the testing accuracy. b) Maintain the pressure for at least 3 minutes. c) Where no leaks are detected, shut off the air supply. d) Where the pipeline fails the test, re-pressurise to 25 +5,−0 kPa and check for leaks by pouring a concentrated solution of soft soap and water over accessible joints and fittings. e) Repair any defects, then repeat steps (a) to (c). f) With the air supply shut off, monitor the pressure for the time intervals given in table. The test length shall be acceptable where the pressure drops by 7 kPa, or less, over the required (tabulated) test period. Note – (1) The test length of pipeline should be restricted to pipeline sections between maintenance holes (the most convenient places for inserting test plugs or fixing temporary bulkheads). The method should not be used for test lengths in excess of 250 m and for pipe diameters larger than 1500 mm. (2) The procedure for low pressure air testing of large diameter pipelines is potentially hazardous because of the very large forces to be resisted by temporary plugs or bulkheads and the serious consequences of accidental bulkhead blow-out. A relief valve, with a 50 kPa maximum setting, should be installed on all pressurising equipment. A-2) Hydrostatic test The test length shall be acceptable where the make-up water added is less than the specified allowable. Where not specified, the allowable make up water shall be 0.5 L/hour per metre length per metre diameter. Hydrostatic test procedure The procedure shall be as follows: a) The test pressure shall be not less than 20 kPa, or 20 kPa above the groundwater pressure at the pipe soffit at its highest point, whichever is the greater, and not exceed 60 kPa at the lowest point of the section. b) Steeply graded pipelines shall be tested in stages where the maximum pressure, as stated above, will be exceeded if the whole section is tested in one length. c) The pressure shall be maintained for at least 2 hours by adding measured volumes of water where necessary. d) Any visible leaks detected shall be repaired and the pipeline shall be retested. B) Pressure pipelines general requirements – Field hydrostatic pressure testing Hydrostatic pressure testing requires selecting an appropriate configuration of method, pressure, and length of test section. Compressed air testing shall not be permitted for pressure pipe. Test parameters and details shall be determined with due consideration to the following: a) Pipe material b) Pipe diameter c) Length of test section d) Duration of the test e) Magnitude of test pressure and rate of pressurisation f) Presence of air in the pipeline g) Time required for saturation of porous liners
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 75 of 92 h) Potential movement of pipeline thrust restraints i) Design pressure for thrust and anchor supports j) Accuracy of test equipment k) Ambient temperature changes during testing l) Presence of leaks in equipment used for testing or equipment attachment points (such as sealing plugs) m) Potential for leaks in the pipeline B-1) Selection of test pressure The hydrostatic test pressure at any point in the pipeline shall be: a) Greater than the design operating pressure; and b) Less than 1.25 times the rated pressure of any pipeline component. Note – The design pressure is the maximum system pressure at a point in the pipeline, considering future developments, static pressure, dynamic pressure and an allowance for short-term surge pressure (water hammer), as determined by analysis. B-2) Selecting test lengths The pipeline length tested shall be either the whole or a section (capable of being isolated), of the pipeline depending on the length and diameter, the availability of potable water and the spacing between sectioning valves or blank ends. The pipeline shall be divided into test sections such that: a) The hydrostatic test pressure at any point in the pipeline: i. Shall be less than 1.25 times the rated pressure of the pipeline, but not less than the designed working pressure at the lowest pressure point (highest elevation point where pipe is tested on a sloped installation); and ii. Is less than 1.25 times the rated pressure of any pipeline component; b) Test sections shall be limited to pipe of the same material. Consideration shall be given to the pressure loading time at the maximum filling rate (see B-3) in determining the test length; and c) Water is available for the test together with facilities for its disposal, in accordance with regulatory requirements, after the test. Note - Watercare recommends that test sections be done as short as possible to reduce the efforts during fault finding should a test length fail to pass the test. The following should be considered: (1) Where long lengths are to be tested, radio or other electronic means of communication between test operatives to coordinate test procedures and thus minimise the test duration is desirable. (2) Long test sections may incorporate a large number of mechanical joints which should be checked for leakage. The longer the test section the harder it is to locate a leak or discriminate between a leak and other effects such as the absorption of air into solution under pressure. B-3) Pre-test procedures The pre-test procedures are as follows: a. All required temporary and permanent thrust blocks shall be in place, and all concrete shall be adequately cured (normally a minimum of 7 days). b. Blank flanges or caps shall be installed at the beginning and end of the test section. Testing shall not take place against closed valves. Mechanical ends that are not end load resistant shall be temporarily strutted or anchored, to withstand the test pressures without movement. c. Pipe ends shall be capped with suitable restrained end caps that will sustain the full test pressure. For steel pipe the Watercare standard test cap detail drawing shall be used. Note – Temporary supports should not be removed until the pipeline has been depressurised. All test personnel should be informed of the loading limits on temporary fittings and supports. d. Where practicable, all bolted joints shall be left exposed to allow for re-tensioning during or after testing.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 76 of 92 e. Compacted embedment and fill material shall be placed to leave all joints, service connections and ball valves exposed wherever possible. f. For PE pipelines, the pressurising time shall not exceed 45 minutes. Note – The pressurising time affects the duration of the PE pipeline test. g. The test equipment shall be placed in position and checked for satisfactory operation. h. The pump shall be of adequate size to raise and maintain the test pressure. Note – A pump that is too small may increase the test duration or where too large it may be difficult to control the pressure. i. Two calibrated test gauges shall be used to cross check gauge accuracy. j. Slowly fill the test length of pipeline with water, preferably from the lowest point, ensuring air is vented at the high point valves. Allow a period between a minimum of 3 hours and 24 hours (preferred), for the temperature of the test length and the test water to stabilise and for dissolved air to exit the system. The recommended rate of filling shall be based on a flow velocity of 0.05 m/s, calculated from the following equation: Qf ≤12.5πD2 where Qf = filling rate, in litres per second D = pipe diameter, in metres Note – The slow rate of 0.05 m/s avoids air entrainment when the filling water is cascading through downward gradients along the pipeline. The period of stabilisation will depend on pipe dimensions, length, material, longitudinal profile, and air exit points. For cement-mortar lined pipe, the pipeline shall be filled at least 24 hours before the commencement of the test, to allow the lining to become saturated. A firm foam swab may be used ahead of the fill water to assist air removal especially where the pipeline undulates. Extract the swab at a high-point wash-out. The swab must be removed prior to testing. Typical pressure test equipment and location are shown in figures B-4-1 and 2. B-4) Post-test procedures After testing, pipelines shall be depressurised slowly. All air venting facilities shall be open when emptying pipelines. The test water shall be drained to an approved waterway and all connection points shall be reinstated.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 77 of 92 Figure B-4-1 – Typical pressure pipeline under field hydrostatic test Figure B-4-2 – Typical field pressure test equipment layout (designed as appropriate to the test pressure)
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 78 of 92 B-5) Constant pressure test (water loss method) – PVC, DI, GRP, and steel pipelines This test is applicable for PVC, DI, GRP, and steel pipelines. The procedure shall be as follows: a) Close all valves apart from the test pump input and pressurise the test length to the specified test pressure (STP) – (see B-2). b) Apply and then maintain the test pressure by the addition of measured and recorded quantities of make-up water at regular intervals over a period, in the range of 1 hour to 12 hours. c) Where pressure measurements are not made at the lowest part of the test length, make an allowance for the static head, between the lowest point of the pipeline and the point of measurement. The quantity of make-up water necessary to maintain the test pressure shall comply with the following equation: Q ≤0.14LDH Where: Q = allowable make-up water, in litres per hour L = length of the test length, in kilometres D = nominal diameter of the test length, in metres H = average test head over length of pipeline under test, in metres Note – The make-up water is not a leakage allowance, but is an allowance to cover the effects of the test head forcing small quantities of entrapped air into solution. Normally the test should last for a minimum of 2 hours and be concluded within 5 to 8 hours. The make-up water requirement should reduce with time as air goes into solution. Where, after 12 hours the make-up water still exceeds the allowable limit, testing should cease and the cause of loss investigated. Acceptance: a) The test length shall be acceptable where there is no failure of any thrust block, pipe, fitting, joint, or any other pipeline component. b) There is no physical leakage. c) The quantity of make-up water necessary to maintain the test pressure complies with the quantity calculation. B-6) Pressure decay test for PE pipe larger than DN200 or longer than 250m This test procedure is applicable to Polyethylene pipe of larger size and length or where larger water systems are being tested (up to 1000m). An alternative test is the static pressure test for PE pipe in section B-9). The procedure shall be as follows: a) Close all valves apart from the test pump input and pressurise the test length to the specified test pressure (STP) – (see B-2). The pressure loading time shall not exceed 45min. b) Once the STP is reached with the conditions met, the pipe line is isolated and pressure allowed to naturally decay. c) Pressure decay over time in viscoelastic pipe is an exponential form and expressed in a calculated ratio as follows:
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 79 of 92 Take a first reading of pressure P1 at T1, where T1 is equal to the pressure loading time (TL). - Take a second reading of pressure P2 at 7TL. Let this be T2. - Take a third reading of pressure P3 at 15TL. Let this be T3. - To allow for this stress relaxation behaviour of PE pipelines, calculate the corrected values of T1, T2 and T3. • Calculate corrected T1: T1C = T1 + 0.4TL • Calculate corrected T2: T2C = T2 + 0.4TL • Calculate corrected T3: T3C = T3 + 0.4TL d) Calculate decay slope ratio (N) values • Calculate N1: 𝑁𝑁1 = (𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙1 − 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙2) (𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙2𝐶𝐶 − 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙1𝐶𝐶) • Calculate N2: 𝑁𝑁2 = (𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙2 − 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙3) (𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙3𝐶𝐶 − 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙2𝐶𝐶) Acceptance: • For pipe HDD drilled or with compacted backfill: N1 and N2 range within 0.04 to 0.05; or • For pipe without backfill or soil support (i.e. slip lines or above surface): N1 and N2 range within 0.08 to 0.10; and • There is no physical leakage. • There is no failure of any component, movement of permanent thrust block or temporary thrust restraint used for testing. • Should the test fail, after the problem has been repaired the test shall be redone completely. Interpretation of results: • For N below 0.04 there is a likelihood of air in the system • For N is above 0.1 indicates a leakage
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 80 of 92 • Where N is above or below the range for the backfill type inspect the graph slope: o Gradual slope is acceptable and N value may indicate a trench obstruction or small amount of air. Can be accepted o An initial steep grade followed by a gradual slope indicates a pressure sensitive fitting or component that leaked under higher pressure but restored under lower pressure. Accept pipe but inspect fittings o A steep change in gradient indicates a leak. The pipeline cannot be accepted. B-7) Pressure rebound test for PE up to DN 200 This test is applicable to PE and ABS pressure pipelines up to typically 250m length or shorter as to allow rapid pressure reduction when bleeding the system for the rebound test. The test rig shall be a recently calibrated pressure transducer, data logger, and check pressure gauge that has a dial of at least 100 mm diameter and a pressure range that places the specified test pressure (STP) (see B-2) in the range 35% to 70% of the gauge’s full scale. The transducer and the check gauge shall read within ±5% of each other. If they do not agree within this tolerance, the equipment shall be recalibrated or replaced. Procedure: a) Prepare the pipeline in accordance with B-3) pre-test procedure. b) Make sure that all air is expelled before commencing with the test and that no air is introduced into the section being tested. c) Maintain the STP for 30 minutes by additional pumping as required. d) Check for obvious leaks. e) After 30 minutes at the test pressure, reduce this pressure rapidly by bleeding water from the system (<5min), to a nominal pressure of 2bar at the test gauge. f) Close the control valve and isolate the test section. g) Record pressure gauge readings at 5 minute intervals for 1 hour after isolation. The test length shall be acceptable if: a) There is no failure of any thrust block, pipe, and fitting, joint, or any other pipeline component. b) There is no physical leakage. c) The pressure rises and then remains static or slightly increases during the 1 hour period. d) This test may be reduced on approval from Watercare to 30min in the rebound phase where there is an operational need to bring the pipe into service quickly. e) If the pressure does not rise, or falls after an initial rise the test is a fail. f) Should the test fail, after the problem has been repaired the test shall be redone completely. B-8) Visual test for small pressure pipelines This test is applicable for small pipelines of all materials, less than 20m in length, and pipelines without joints other than the end connections (such as coiled pipe). The procedure shall be as follows: a) The test pressure (see B-2) shall be applied and the test section isolated by closing the high point air release valves and the pump feed valve. b) The test section shall be visually inspected for leakage at all joints, especially bolted joints, all fittings, service connections, and ball valves. c) Pressure gauges shall be checked to ensure that pressure has not fallen significantly indicating an undetected leak. d) Any detected leak shall be repaired and the section shall be retested. e) Where no leak is detected, high point air release valves shall be opened, the pipeline shall be depressurised to slowly drain the line into an approved waterway and all connection points shall be reinstated. The test length shall be acceptable where: a) There is no failure of any thrust block, pipe, fitting, joint, or any other pipeline component.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 81 of 92 b) There is no physical leakage. c) There is no pressure loss indicative of a leak. d) Should the test fail, after the problem has been repaired the test shall be redone completely. e) B-9) Hydrostatic pressure test for PE pressure pipelines This test is applicable for PE pipelines larger than DN200 and/or longer than 250m and as an alternative to the pressure decay test in B-6). The test method shall be as described by ASTM F2164-13. Procedure: a) The pipe to be tested shall be selected and prepared as per section B-1) to B-3) b) Allow the test section and test liquid to equalise to common temperature c) Initial expansion – gradually increase pressure to the test pressure. If leakage occur or the test pressure cannot be reached the pipe must be repaired before proceeding with the test. d) Add make-up water as required to maintain the maximum test pressure for 4 hours. e) Reduce the test pressure by 69 kPa and monitor for 1 hour – do not increase pressure or add make- up water. Acceptance: a) There is no visible leakage. b) The monitor period of 1 hour remains at steady pressure within 5% the reduced test pressure. 10.5.2 Manhole and chamber (concrete) testing The type of test shall be selected according to the performance requirement of the system, the type of installation methodology, ground conditions and Health and Safety risk factors associated with the installation. All manhole tests shall include 300mm of the connecting pipework with the lid fitted into place unless otherwise stated. A) Hydrostatic testing of concrete manholes This test may be used for manholes up to 3.5m depth and relies on obtaining a proper seal from the pipeline plugs to withstand the hydrostatic pressure. The limitation on this test is the un-uniform pressure distribution and the zero pressure at the top of the manhole will not sufficiently test the top seal of the lid. To test the top seal this test shall be supplemented with the visual check (smoke test) in Section 10.5.2 D) or the low pressure air test as per Section 10.5.1, A-1). The manhole shall be completely backfilled and interconnected pipework and manholes be vacated before starting the test. Pre-test procedure: Ensure that there is no entry into the connecting trench or any connected manhole associated with the manhole being tested. The manhole shall not be pressurised beyond the static pressure and the access hatch shall remain open. Procedure: a) Seal pipe or sleeve openings using properly sized or inflatable plugs. b) Completely fill the manhole to the top of the lid frame with water. c) Allow the filled manhole to soak for minimum 4 hours. d) Top up any water loss to the top of the lid frame during the soak period. e) Measure the water loss over every 1 hour for 8 hours. f) Empty the manhole and allow standing for 1 hour before doing a visual inspection for groundwater infiltration. Acceptance: The average quantity of make-up shall not be more than 0.3 litres per 1m diameter per 1m depth per hour. The post-test visual inspection shall show no evidence of groundwater ingress through any joint.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 82 of 92 B) Vacuum test The vacuum test creates differential pressure between the inside and outside of the manhole. This test shall be completed with the manhole completely backfilled and the lid in place. Procedure: a) Clean manhole thoroughly. b) Seal openings using properly sized or inflatable plugs. c) Connect seal plate to manhole opening. d) Draw vacuum of -254mmHg (or -338.6mbar) and isolate valves. e) Hold test time according to the manhole sizes as listed in the table below: Depth (m) Diameter (mm) 675 900 1050 1200 1350 1500 1800 2400 3000 Time (s) <2 11 14 17 20 23 26 33 39 45 3 14 18 21 25 29 33 41 49 57 3.5 17 21 25 30 35 39 49 59 69 4.3 20 25 30 35 41 46 57 69 81 5 22 29 34 40 46 52 67 81 95 5.5 25 32 38 45 52 59 73 87 101 6 28 35 42 50 53 65 81 97 113 6.5 31 39 46 55 64 72 89 107 125 7 33 42 51 59 68 78 97 115 133 8 36 46 55 64 75 85 105 125 145 8.5 39 49 59 69 81 91 113 135 157 9 42 53 63 74 87 98 121 145 169 9.5 46 58 69 81 94 105 129 153 177 10 49 63 74 87 98 113 139 165 191 f) Release the vacuum and remove the test gear and plugs. Acceptance: a) For the duration of the test the vacuum did not drop below -228mmHg (or -304mbar). b) There are no visible wet patches or “sweating” at any of the pipe penetrations, seals or riser joints. C) Infiltration test This test is completed by creating an external water column around the manhole that will force groundwater through any leaking joints. This method is recommended where manholes are over 3.5m deep or that can only be part tested using the hydrostatic testing method up to 3.5m depth. However the limitation on part testing
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 83 of 92 to 3.5m is that the hydrostatic pressure shall be demonstrated to be higher than the groundwater pressure at the location of the joints being tested. The vacuum test procedure is preferred over this option. This test does not confirm the lid seal and shall be supplemented with the visual check (smoke test) in Section 10.5.2, D) or the low pressure air test as per Section 10.5.1, A-1). Procedure: a) Excavate or provide a shallow moat of approximately 500mm width around the circumference of the manhole and fill with water. b) A 32mm PVC sleeve is inserted into the ground adjacent to the manhole wall to 1m below the hydrostatic test depth. The bottom 1m of the sleeve shall be perforated to allow groundwater to enter the sleeve. c) The water in the moat is filled until the groundwater in the sleeve reaches the level of the water in the moat. d) The groundwater level is maintained for eight (8) hours. Acceptance: There are no visible leaks, wet patches or “sweating” at any of the pipe penetrations, seals or riser joints. D) Visual check (smoke test) This test shall only be conducted on manholes where the joints and pipe penetrations being tested have not been backfilled over and are visible for inspection of forced smoke leaking through defective seals. The limitation of this test is to manholes that are not located within a 100 year flood plain level and is suited for low risk shallow manholes only. Procedure: a) Seal openings using properly sized or inflatable plugs. b) Connect seal plate to opening of manhole lid with appropriate connection to introduce the smoke. c) Introduce smoke into manhole being tested according to the manufacturer’s recommendation. d) The smoke shall be introduced for a minimum of 5 minutes. e) Inspect joints for smoke leaks. Acceptance: There is no smoke leaking from any of the joints. 10.5.3 Manhole (plastic/GRP material) testing Manholes shall be tested twice: a) Off-site as a single unit at the manufacturer’s facilities according to industry best practice for the material being used; and b) On installation on site, fully backfilled and connected, and tested per the vacuum test described in Section 10.5.2-B). The material testing sheets shall be made available for record purposes; having undergone Watercare’s pre- approval of the product being installed. 10.5.4 Fluid retaining structures (process tanks, reservoirs, etc.) This section relates to the testing requirements for single layer fluid storage structures with no pressure applied other than the gravitational weight of the fluid retained. These tests are not for manholes or man access chambers. A) Concrete tanks The test is to demonstrate fluid loss of less than 0.05% of the tank volume per 24 hours period. The test should be conducted long enough to produce at least 15mm drop in the level. The leakage rate is proportional to the depth of water over the leakage point with leakage at the bottom of a tank generally contributing more to the total leakage than a similar defect at a higher level in the tank. For odd shaped tanks such as clarifier tanks the
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 84 of 92 depth shall be expressed as a calculated equivalent depth when determining the minimum test duration time, in example: Conical structure: Determine equivalent depth (d) = (H2 x A + [(H1-H2) x A] /3) /A Determine test time = 0.015/(0.05 x (d)x∏r² ) = test days (round up) Where: H1 = maximum/full water depth H2 = side wall height A = area r = radius A further impact on leakage rate determination is the surrounding media of the tank where groundwater could push back on a leak. Unsupported wall structures may deflect. Open lids or ventilation and temperature changes may affect the test results and needs to be accounted for. Evaporation per hour: Eh = Ɵ A (Xs – X) Ɵ = (25+19 V) where V = velocity of air above water surface A = surface area (open to evaporation) Xs = humidity ration in saturated air Air Temp ᵒC Humidity in saturated air (Xs) 0 0.003767 5 0.005387 10 0.007612 15 0.01062 20 0.014659 25 0.019826 30 0.027125 X = average humidity ratio over test period Temperature expansion/contraction: ΔV = β Vo ΔT β = Volumetric temperature expansion coefficient (use 0.000214 for water) ΔV = change in volume Vo = volume of water ΔT = temperature change Pre-test procedure: a) The structure must not be backfilled; or b) Where backfill is required as part of the structural integrity design, it shall be ensured that the surrounding soil is not ground water charged. A monitoring bore(s) up to 500mm below the tank foundation shall be provided to monitor ground water levels. If groundwater is present it shall be removed before testing may proceed. c) Fill the tank with water whilst monitoring all outlet drains, connecting pipes and valves, structural joints, etc. for visible leaks. d) The structure shall be kept filled with water for minimum 3 days before testing may commence. H2 H1 d
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 85 of 92 Procedure: a) Confirm positions for measurements from at least two locations 180ᵒ apart. On larger tanks it is best to spread locations 90ᵒ apart (for 4 locations) to allow for settlement. b) Measure test starting level. c) Measure test start water temperature at depths of 500mm below the water surface level and at 2m intervals to the full depth of the tank. d) Calculate test time required. e) Repeat measurement every 24 hours. f) Compute leakage rate over test period. Account for evaporation and temperature change. Where the tank top is sealed ignore evaporation rate. Where the temperature is measured to be constant between measurements, ignore affects. Acceptance: Average water loss < 0.05% of total volume per 24 hours of testing. B) PE, GRP, steel tanks The test is to demonstrate fluid loss of less than 0.025% of the tank volume per 24 hours period. The test should be conducted long enough to produce at least 15mm drop in the level. Follow the test procedures as for A) concrete tanks. The saturation period of 3 days as part of the pre-test procedures is not required. Acceptance: Average water loss < 0.025% of total volume per 24 hours of testing. 10.6 Potable water infrastructure disinfection Pipelines, tanks and reservoirs for potable water use shall be disinfected in accordance with Watercare’s Code of Practice for water reticulation disinfection. 10.7 Concrete – buildings and structures NZS 3109 to clause 9 by NATA/IANZ accredited laboratory. 10.8 Shotcrete A test panel at least 1200mm x 1200mm for each mix being considered, the same thickness as the intended structure, using the same construction equipment and for each shooting position to be encountered (i.e. slab, vertical and overhead sections). Provide in the test panel the same reinforcement as intended for the structure in at least half of the panel, to test for proper embedment of reinforcing steel. Sample four cores from the panels for testing at 7 days and 28 days. All cut or broken surfaces shall be dense and free from laminations and sand pockets. In addition to the concrete testing requirements of NZS 3109 clause 9, complete to NZS 3112 test two 50mm cores recovered from every 75m² of the actual construction. Tests shall be completed by a NATA/IANZ accredited laboratory. Complete ultrasonic or impact hammer test across the construction area to determine overall uniformity to the specified thickness. 10.9 Masonry NZS4210, tests per Appendix 2 of the New Zealand standard. 10.10 Testing of plumbing installations Hot and cold water pipework, fully installed; carry out a hydraulic test of 1.25 times the static head with a minimum of 1200 kPa for a period of 60 minutes. There should be no visible leaks and zero pressure loss.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 86 of 92 10.11 Timber moisture content NZS 3602, General 16%-20%. Heated installation functional area <10%. 10.12 Direct current voltage gradient (DCVG) coating defect survey for new steel pipelines 10.12.1 DCVG survey types Construction DCVG survey: conducted during the installation of a new pipeline. The survey shall be conducted as outlined in the approved construction management plan. This survey shall be undertaken with the probes positioned over the pipeline, after backfilling of the trench has occurred and prior to sealing the surface with either bitumen or concrete. As this type of survey will generally be done in shorter sections, particular care must be taken when determining chainages and marking of defects. Commissioning DCVG Survey: completed after installation and construction DCVG survey has been completed. Where the pipeline runs under a sealed surface such as concrete of bitumen, the survey shall be conducted with the probes positioned in a suitable electrolyte (such as soil) as close as practicable to the centre line of the pipe. Where the pipeline runs under a sealed surface, Watercare shall define whether the surface can be saturated with water, or holes must be drilled through the surface to provide suitable contact with the electrolyte. 10.12.2 Minimum qualifications Task Minimum Level of Expertise Field inspection and testing Corrosion Technician with minimum 2 years’ experience in corrosion testing including specific training and experience related to coating defect surveys on pipeline, under the indirect supervision of a Corrosion Technologist Analysis and approvals Corrosion Technologist with a minimum 10 years’ experience in corrosion testing including specific experience related to coating defect surveys on pipelines or Corrosion Technician under the direct supervision and with report review and approvals of a Corrosion Technologist. Proof of suitable qualification shall be provided to Watercare. 10.12.3 Testing 10.12.3.1 Visual inspection & preliminary tests Prior to undertaking the DCVG survey, the following inspections and tests shall be undertaken: a) Record the locations of all electrical earths in the survey report. b) Record locations of all sacrificial anode beds in the survey report. Note - Electrical safety earth beds, such as those installed for the protection of personnel and equipment and mitigation of low frequency induced (LFI) a.c. currents are not to be disconnected from the pipeline unless safe to do so. 10.12.3.2 Method The body of Australian Standard AS4827.1 – 2008 Coating defects surveys for buried pipelines Part 1: Direct current voltage gradient (DCVG) provides “normative” advice on coating defects surveys and may be used as an additional guide to testing. However this document supersedes AS 4827.1 when working on Watercare’s assets. a) Signal application Minimum test point swing is 1000mV. Lower strengths may only be used if it can be shown that a defect of 0.1% IR will be detected from the equivalent methodology. The DCVG survey signal may be derived from the installed CP system power supply or applied using portable transformer/ rectifier unit utilizing the system anode ground bed or temporary earth electrode.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 87 of 92 Should stray current have significant impact on the accuracy of measured defect IR signals, the sizing of defects shall be undertaken during the period when there is no stray current. b) Survey methodology Determining DCVG Signal Amplitude to Remote Earth At Test Points The procedure to determine the DCVG signal amplitude to remote earth at test point is as follows: i. Place 1 reference electrode at the base of the test point or other electrical contact point with the soil, while the second electrode contacts the test point or other properly cleaned electrical point in contact with the structure. The potential swing measured by this arrangement is the DCVG signal amplitude between the pipe and the base of the test point. ii. Measure the voltage gradient from the base of the test point to remote earth by placing 2 probes which are separated on the ground adjacent to the test pipes (unless it was already established that there is no defect causing a voltage gradient adjacent to the test point). These 2 probes are then moved perpendicular in convenient steps at 90 degrees to the pipeline route measuring potential swings until remote earth is achieved. The sum of all potential swings of each step is then calculated from the base of the test point to the remote earth. (NOTE: Well coated pipeline may have a voltage gradient from the base of the test point to remote earth that is negligible unless a coating defect is in close proximity). In most cases, the DCVG signal measured in step (i) will adequately represent the total DCVG signal amplitude at the test point. iii. The total DCVG signal amplitude at a test point or other connection point is the sum of (i) and (ii) c) Recording of defects All defects located during the coating survey shall: • Be sized to remote earth and the IR drop recorded in mV • Be marked by driving in a peg or by fluorescent paint where a peg cannot be used. • Defect information shall recorded that includes: o GPS location recorded in NZTM (datum 2000) map coordinates, to the accuracy levels described in the Watercare Data and asset Information standard. o Description of the location with reference to the pipeline length, house number, distance from driveway, and other reference details noted to facilitate future re-location of the defect. o Offset from pipeline if the defect could not be centred on the pipeline. A sample format is provided below: Defect Number Metreage GPS Coords East- North Description of Location IR (mV) Example: Defect Number Metreage GPS Coords East- North Description of Location IR (mV) - 0 2661231- 6491234 Test point swing. TP1 1500 1 103 2661789- 4m d/s of d/s edge d/way 200 Smith St 5
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 88 of 92 6491456 2 622 2661756- 6491789 2m u/s of power pole 21 Brown Rd 7 - 850 2661900- 6491551 Test point swing. TP2 1200 d) Coating defect survey - % IR calculation Defect sizes shall be related in terms of %IR by calibrating the measured IR sizes (mV) at defects against the signal size (mV) calculated to exist at the defects’ location. The signal size shall be determined from the measured signal size relative at a suitable number of “calibration” points along the pipeline, and attenuation of the signal shall be taken into account between the “calibration” points. Details of the survey and assessment, including calculated defect sizes (%IR), signal size the electrode potential survey data, shall be reported to Watercare for approval and acceptance immediately upon completion of the survey. Upon determining the epicentre of the coating defect, a series of lateral stepped potential swings shall be measured, moving from the epicentre toward remote earth. Note that lateral potential swings decay exponentially from the defect and remote earth is located when the lateral DCVG signal amplitude in subsequent steps is negligible compared to the sum of potential swings to that location. The sum of the potential swings is the IR component over the line of the coating defect to remote earth (SOL) and will be used for calculating “ %IR ”. Figure 10.12-1 depicts how SOL is calculated. Figure 10.12-1: Sum of potential swings Hence, the series of lateral mV readings to remote earth is summed to obtain the SOL. This is defined by equation below:
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 89 of 92 SOL = (V1 + V2 + V3 + V4 + V5 ) mV If a defect is located, the %IR is calculated as the IR drop between a point on the ground directly above the coating defect and remote earth, expressed as a percentage of the estimated signal amplitude between the coating defect and remote earth. This is shown by the equation below: %IR = (SOL x 100) / SCF Note – • Digital voltmeters (DVMs) are not sufficiently accurate to obtain the difference between the ‘on and off’ pipe-to-soil potentials. • The DVM’s sample rate and screen update may not be synchronised with the DCVG pulse. • To reduce error, use the same DCVG instrument for all readings for a given %IR calculation, unless an accurate calibration between instruments has been established. 10.12.4 DCVG survey procedures The application of the DCVG survey technique is as follows: a) The surveyor should walk above the centreline of the buried pipeline and place one probe electrode in front of the other in the soil. Probes should be moist to provide good contact with the electrolyte. This may require the application of water to the electrolyte if the soil is dry or the survey is conducted over a small concrete surface. Should the pipeline run under a sealed road or large concrete surface (such as car park or building foundation), Watercare shall approve the methodology. b) The probe electrodes should be separated approximately 1.0 to 2.0 metres parallel and above the pipeline searching for voltage gradients along the pipeline. If perpendicular probes are used, one probe should always be directly above the pipeline where achievable. c) The DC offset and range selector switch is used to bring any pulse onto the meter scale. d) If a pulse is seen on the meter scale, the direction of the metre indicator deflection is observed as it points toward the electrode that is closest to the coating defect, assuming the electrode closest to the defect is connected to the negative terminal of the voltmeter. Opposite connections will cause the indicator to swing the other way. e) As the coating defect is approached, the amplitude increases and then reverses when the coating defect is passed. (If using perpendicular probes, the maximum indication will be observed when the probe above the pipeline is directly above the defect. Reversal will not occur once the defect is passed, only a reduction in amplitude). f) When a reversal of pulse direction is observed, this indicates a coating defect has been traversed. The coating defect location may be identified by retracting slowly to where no pulse is observed. The coating defect epicentre then lies midway between the 2 probe electrodes, and is normally marked by a line on the ground. g) The surveyor turns 90 degrees to the pipeline and the null process is repeated. A second line is marked, and the location where the two cross is the coating defect epicentre. This location is directly above the actual coating defect. Note - Max spacing between measurements of 5m in rural areas. Depending on signal strength, drilling through tar-seal may be required to achieve a suitable contact with the electrolyte if a suitable swing is not achieved on the berm of the road. • All defect indicators are to be precisely located and recorded. Any indication too small to be precisely located is to be recorded against the meterage range where it was identified. • When surveying over concrete, the concrete shall be wetted to obtain a suitable contact for the probes. • During construction survey (where the pipe has not been connected) all dirt shall be cleared away from bare steel (i.e. uncoated pipe ends, weld plates, AV connections). • In areas with low swing, closer spacing between readings shall be used in addition to greater spacing between probes.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 90 of 92 10.12.5 Acceptance criteria The following coating performance acceptance / rejection criteria shall apply to all steel pipelines. Other criteria may be adopted by Watercare for other types of coating system subject to sufficient justification of alternative criteria. Watercare shall define the criteria to adopt for existing mains prior to beginning survey. a) All defect indications equal to or greater than 0.2% IR shall be excavated and repaired providing there is no evidence to indicate that the indications are associated with anodes, or electrical earth (defects at test leads should be excavated no matter the size, as these are likely to be shielded and have different metals). b) Defects less than 0.2% IR shall be subjected to the following assessments: i. If a defect measuring ~ 0.2%IR is excavated and shown to be a significant size, then the next largest shall be excavated to determine the actual size of the defect. This process shall be completed until Watercare determine that the defect is insignificant. ii. Where two or more defect indications are separated by a pipe spool length, at least one shall be excavated, inspected and repaired. If the first indication is found to be at a pipe weld joint the other defect(s) shall be excavated. iii. Should isolated defects of this size (less than 0.2%IR) be located they may not require excavation and repair subject to the following provision: If the specified over-the-line electrode potential survey indicates that a polarized protection level (free of IR component and other interference) of at least 100 mV more negative than the minimum protection criteria specified for the pipeline can be achieved at all points along the affected pipeline section with a total protection current not exceeding 50 mA per kilometre length of the pipeline. All the defects shall be recorded for future reference. c) Chambers with water, chambers without water- Where a defect is located at a chamber the Watercare shall advise the criteria to adopt. Tees, joints, welds, cadwelds: - All defects located at Tees, joints, welds and cadwelds must always be repaired 10.12.6 Re-test following defect correction Following rectification of coating defects, details of repairs to the coating and subsequent performance measurements indicating the success of the repair shall be recorded on the pro-forma and supplied to Watercare for retention. All repairs are to have a DCVG carried out following backfill (this may be carried out after the pipe has a minimum of 300 mm cover). It is advised that the pipe either side of the excavation be DCVG tested while the defect being inspected is exposed, to ensure that no defects exist immediately up or downstream of the excavation that may have been shielded by the defect being inspected. The following table shall be used for recording corrected defects.
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 91 of 92 Logging of defects and repairs: Defect Number Metreage (m) GPS Coords Description of location IR (mv) %IR (I)nspected/ (R)epaired/ (N)ot Repaired Description of defect Likelihood of shielding (H)igh (M)edium (L)ow Photo Number/ Name Date Inspected/ Repaired DCVG Survey
Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 92 of 92 10.12.7 Report All test results shall be recorded and a separate report supplied to Watercare for assessment and acceptance prior to undertaking commissioning of the CP system for the pipeline. A record of defects shall be submitted to the Watercare for review following the assessment against the acceptance/ rejection criteria and a recommendation for proposed remediation where required to meet the criteria. The report shall contain the following as a minimum: a) Pipeline details including route length, diameter, fittings, off-takes, safety earths, sacrificial anodes and CP system components b) Details of equipment and methodology including method and location of signal injection points and strength of signal c) Potential survey results including output current and voltage of the direct current (CP) power source d) Listing of all coating defects located including reference points and GPS identification e) Where specified in this document, size of defects in term of lateral IR, signal size at calibration points, and calculated defect size represented as %IR f) Assessment of defect %IR sizes against the acceptance / rejection criteria in this document g) Recommendations for excavation, physical sizing and repair of defects h) Provide details of repairs undertaken and subsequent coating survey results indicating the criterion has been satisfactorily achieved. i) Photo record of defects during repairs 10.13 Mortar rehabilitation (lining repair) Samples and tensile bond strength tested to AS1012 part 24.

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general_civil_construction_standard.pdf

  • 1. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 1 of 92 General Civil Construction Standard No. CG Ver.1.1 Date: 19 June 2019
  • 2. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 2 of 92 Revision Description Released By Date 0.1 First draft J de Villiers 8/10/2015 1 First release J de Villiers – Principal Engineer, Standards 14/10/2016 1.1 Updates to pipeline testing, location of pipe services and standard references. Document formatting changes J de Villiers 19/06/2019 Reviewers: Version 1.1: Simon Porter – Head of Service Delivery, Operations James Eardley - Projects Manager, Infrastructure Construction Graham Nairn – Asset specialist, Civil Operations Andrew Mercer – Site Engineering Manager Version 1: Martin Smith – General Manager Strategy and Planning, Watercare Geof Stewart – Manager Asset Strategy, Watercare Chris Allen – Wastewater Strategy Manager, Watercare James Eardley - Projects Manager, Watercare Brian Park – Discipline Engineer Water, Watercare
  • 3. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 3 of 92 Summary of changes Version Section Description of revision 1.1 2.2 Selection deleted, serves no purpose to document content 4.1 Text updates to refer Watercare compliance policy 4.2 Text updates to refer commissioning code of practice 5 Section updated with Watercare cross-referenced standards and drawings to be used in conjunction with the construction standard. Minor update of referenced national standards. 6.1 Text revision to delete text duplicated in referenced standard 7; C2.1 Include reference to Watercare HSE standard requirements C2 Minor updates to section to include dewatering consent considerations and terminology corrections C3 Section references included to use manufacturer recommended pipe jointing. Minor wording corrections across section C3.1 Clarification added on expectations for pipe oval checking by pigging or scanning method – added to QA/QC C3.1.5; C3.1.6 Updated text to clarify horizontal and vertical clearances for pipe laying and the allowable tolerances. Note at end of section relocated to prevent misinterpretation. C3.1.7 New section to describe tracer wire installation requirements C3.2 Added discovery protocols for tunnelling works, in addition to HSE. Updated reporting C3.3 Section updated with information to be provided, record keeping and QA requirements for HDD C3.4.1 Clause expanded to clarify when pipe curving may be accepted for gravity or ducted services. C3.4.2 Removed duplication of bend manufacturing. Referred to material supply standard C3.10.1 Minor working changes to clarify use of CCTV before and after lining application C5.1; C5.2 Updated note. Corrected painting code C11 New section describing polymer-type chamber installations 10.5, Table A1 Expanded table to extend testing length 10.5.1 B-6) Section updated to clarify test result interpretation 10.5.1 B-9) New hydrostatic pressure test added for testing PE pipe All sections Added paragraph numbering to improve reference
  • 4. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 4 of 92 Table of contents DEFINITIONS....................................................................................................................................................9 1. INTRODUCTION.....................................................................................................................................11 2. STANDARD DOCUMENTS OVERVIEW.....................................................................................................11 3. QUALITY CONTROL AND QUALITY ASSURANCE .....................................................................................12 4. GENERAL ENGINEERING DOCUMENT SUBMITTAL REQUIREMENTS .......................................................12 5. REFERENCED STANDARDS .....................................................................................................................13 6. MATERIALS............................................................................................................................................16 7. HEALTH AND SAFETY .............................................................................................................................16 8. ASSET CAPTURE.....................................................................................................................................16 9. CIVIL CONSTRUCTION............................................................................................................................17 C1. SITE ROADING ...................................................................................................................................17 C1.1 General ................................................................................................................................................17 C1.2 Paving subgrade preparation...............................................................................................................17 C1.3 Subsoil drains.......................................................................................................................................17 C1.4 Basecourse and sub-base.....................................................................................................................17 C1.5 Asphaltic concrete ...............................................................................................................................17 C1.6 Kerbing.................................................................................................................................................18 C1.7 Stormwater drainage...........................................................................................................................18 C1.8 QA/QC template ..................................................................................................................................18 C2. EARTHWORKS ...................................................................................................................................18 C2.1 General ................................................................................................................................................18 C2.2 Site preparation ...................................................................................................................................18 C2.3 Geotechnical investigations.................................................................................................................19 C2.4 Topsoil stripping...................................................................................................................................19 C2.5 Stockpiling............................................................................................................................................19 C2.6 Excavation support and perimeter protection ....................................................................................19 C2.7 Excavation general...............................................................................................................................19 C2.8 Water in excavations ...........................................................................................................................19 C2.9 Excavation for trenches .......................................................................................................................20 C2.10 Excavation for structures...................................................................................................................20 C2.11 Excavation by hydro-vacuum excavation...........................................................................................20 C2.12 Excavation by explosive blasting........................................................................................................20 C2.13 Excavation material classification......................................................................................................20 C2.14 Backfill and fill in general...................................................................................................................21 C2.15 General compaction of backfill..........................................................................................................21 C2.16 Backfill material classification............................................................................................................21 C2.17 Surface reinstatement .......................................................................................................................22 C2.18 Top soil and grass reinstatement.......................................................................................................22 C2.19 Surplus material.................................................................................................................................22 C2.20 Record keeping ..................................................................................................................................22 C2.21 QA/QC template ................................................................................................................................22 C3. PIPE AND DUCT LAYING .......................................................................................................................23 C3.1 General Pipeline construction .............................................................................................................23 C3.1.1 Position tolerances.........................................................................................................................................24 C3.1.2 Bedding material, pipe surround and compaction.........................................................................................24
  • 5. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 5 of 92 C3.1.3 Pipe laying in embankment............................................................................................................................24 C3.1.4 Pipelines through structures ..........................................................................................................................25 C3.1.5 Parallel pipeline separation............................................................................................................................25 C3.1.6 Vertical separation from other services .........................................................................................................25 C3.1.7 Trace wire installation....................................................................................................................................25 C3.1.8 QA/QC template.............................................................................................................................................26 C3.2 Pipe jacking, boring or tunnelling and shaft sinking ............................................................................27 C3.2.1 General...........................................................................................................................................................27 C3.2.2 Jacking pits, headings and shafts....................................................................................................................29 C3.2.3 Installations under roads or other facilities....................................................................................................29 C3.2.4 Over excavation and grouting ........................................................................................................................29 C3.2.5 Pipe jacking ....................................................................................................................................................29 C3.2.6 Micro-tunnelling.............................................................................................................................................29 C3.2.7 Reinstatement of jacking pits.........................................................................................................................29 C3.2.8 Record keeping...............................................................................................................................................30 C3.2.9 QA/QC template.............................................................................................................................................30 C3.3 Horizontal directional drilling (HDD)....................................................................................................30 C3.3.1 Calculations ....................................................................................................................................................31 C3.3.2 Construction plan...........................................................................................................................................31 C3.3.3 Tracking systems ............................................................................................................................................32 C3.3.4 Drilling fluids and cuttings management plan................................................................................................32 C3.3.5 Contingency plans ..........................................................................................................................................32 C3.3.6 Grouting .........................................................................................................................................................32 C3.3.7 Record keeping...............................................................................................................................................32 C3.3.8 QA/QC template.............................................................................................................................................33 C3.4 Installation of polyethylene pipe .........................................................................................................34 C3.4.1 Pipe curving....................................................................................................................................................34 C3.4.2 Pipe bends and fittings...................................................................................................................................35 C3.4.3 Pipe jointing ...................................................................................................................................................35 C3.4.4 Equipment......................................................................................................................................................36 C3.4.4 QA/QC templates ...........................................................................................................................................38 C3.5 Repair of polyethylene pipe.................................................................................................................40 C3.6 Installation of welded steel pipelines ..................................................................................................40 C3.6.1 Pipe bends and other assemblies...................................................................................................................40 C3.6.2 Pipe joints.......................................................................................................................................................40 C3.6.3 Corrosion protection......................................................................................................................................41 C3.6.4 Concrete lined steel pipe - Wastewater specific requirements......................................................................42 C3.6.5 QA/QC templates ...........................................................................................................................................42 C3.7 Installation of PVC pipelines ................................................................................................................42 C3.7.1 Pipe Joints ......................................................................................................................................................42 C3.7.2 QA/QC template.............................................................................................................................................43 C3.8 Installation of Ductile Iron (DI) pipe.....................................................................................................43 C3.8.1 Pipe Joints ......................................................................................................................................................43 C3.8.4 Pipe deflection with spigot joints...................................................................................................................43 C3.7.2 QA/QC template.............................................................................................................................................44 C3.9 Concrete and Ceramic pipes (Wastewater only) .................................................................................45 C3.9.1 General...........................................................................................................................................................45 C3.9.2 Cutting of pipes ..............................................................................................................................................45 C3.9.3 Pipe Laying .....................................................................................................................................................45 C3.9.4 Laying on a curve............................................................................................................................................45 C3.9.5 Rubber ring joints...........................................................................................................................................45 C3.9.6 Mechanical joints ...........................................................................................................................................45 C3.9.7 Repair .............................................................................................................................................................45 C3.9.8 QA/QC Template ............................................................................................................................................46 C3.10 Pipe structural lining..........................................................................................................................46 C3.10.1 General.........................................................................................................................................................46
  • 6. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 6 of 92 C3.10.2 Access...........................................................................................................................................................46 C3.10.3 Pipeline cleaning ..........................................................................................................................................46 C3.10.4 CCTV requirements ......................................................................................................................................46 C3.10.5 Pipe repairs ..................................................................................................................................................47 C3.10.6 Polymer lining methods ...............................................................................................................................47 C3.10.7 Cement and mortar in-situ lining methods ..................................................................................................47 C3.10.8 Record keeping.............................................................................................................................................47 C3.10.9 QA/QC Template ..........................................................................................................................................48 C3.11 Pipelines brought into service ...........................................................................................................48 C4. CONCRETE........................................................................................................................................49 C4.1 Construction of reinforced concrete structures ..................................................................................49 C4.1.1 Reinforcement................................................................................................................................................49 C4.1.2 Construction joints .........................................................................................................................................50 C4.1.3 Contraction joints...........................................................................................................................................50 C4.1.4 Slump tolerance .............................................................................................................................................51 C4.1.5 Vibration.........................................................................................................................................................51 C4.1.6 Surface finish..................................................................................................................................................51 C4.1.7 Penetrations through structures....................................................................................................................51 C4.1.8 Records...........................................................................................................................................................51 C4.1.9 QA/QC template.............................................................................................................................................52 C4.2 Construction of enclosed chambers, manholes and small structures .................................................52 C4.2.1 General...........................................................................................................................................................52 C4.2.1 Foundation .....................................................................................................................................................53 C4.2.2 Roof slab, lids and access ...............................................................................................................................53 C4.2.3 Infiltration performance.................................................................................................................................53 C4.2.4 QA/QC template.............................................................................................................................................53 C4.4 Shotcreting...........................................................................................................................................53 C4.4.1 General...........................................................................................................................................................53 C4.4.2 Preparation and trial ......................................................................................................................................53 C4.4.3 Placement of shotcrete ..................................................................................................................................54 C4.4.4 Finishing .........................................................................................................................................................54 C4.4 5 Joints ..............................................................................................................................................................54 C4.4.6 QA/QC template.............................................................................................................................................54 C4.5 Formwork.............................................................................................................................................55 C4.6 Concrete defect repairs .......................................................................................................................55 C4.6.1 Patch repairs ..................................................................................................................................................55 C4.6.2 Crack repairs...................................................................................................................................................55 C4.6.3 QA/QC template.............................................................................................................................................55 C4.7 Rehabilitation of wastewater pipe and structures with cement mortar.............................................56 C4.7.1 General...........................................................................................................................................................56 C4.7.2 Surface preparation........................................................................................................................................56 C4.7.3 Mortar application .........................................................................................................................................56 C4.7.4 Record keeping...............................................................................................................................................56 C4.7.5 QA/QC Template ............................................................................................................................................56 C5. PAINTING.........................................................................................................................................57 C5.1 General ................................................................................................................................................57 C5.2 Painting of pipes, equipment and structures.......................................................................................57 C5.2.1 External pipe painting ....................................................................................................................................58 C5.2.2 Internal pipe painting.....................................................................................................................................58 C5.2.3 Painting of buildings.......................................................................................................................................58 C5.3 Field touch-up painting........................................................................................................................62 C5.4 Protection of work and adjacent equipment.......................................................................................62 C5.5 Valve box cover paint colours..............................................................................................................62 C5.6 Painting equipment .............................................................................................................................62 C5.7 QA/QC template ..................................................................................................................................63
  • 7. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 7 of 92 C6. DEMOLITION AND ABANDONMENT ........................................................................................................64 C6.1 General ................................................................................................................................................64 C6.2 Existing work and damage ...................................................................................................................64 C6.3 Protection of people, property and environment ...............................................................................64 C6.4 Removal of material.............................................................................................................................64 C6.5 QA/QC template ..................................................................................................................................64 C7. MASONRY........................................................................................................................................64 C7.1 Workmanship.......................................................................................................................................64 C7.2 Materials handling and block types.....................................................................................................65 C7.3 Laying of masonry................................................................................................................................65 C7.4 Clean-out ports ....................................................................................................................................65 C7.5 Control joints .......................................................................................................................................65 C7.6 Reinforcement .....................................................................................................................................66 C7.7 Filling cores ..........................................................................................................................................66 C7.8 QA/QC template ..................................................................................................................................66 C8. PLUMBING .......................................................................................................................................66 C8.1 General ................................................................................................................................................66 C8.2 QA/QC template ..................................................................................................................................67 C9. CARPENTRY ......................................................................................................................................67 C9.1 Workmanship.......................................................................................................................................67 C9.2 Fasteners and fixings............................................................................................................................67 C9.3 Timber treatment ................................................................................................................................67 C9.4 Timber sizes .........................................................................................................................................68 C9.5 Framing................................................................................................................................................68 C9.6 Moisture content.................................................................................................................................68 C9.7 Material handling.................................................................................................................................68 C9.8 QA/QC template ..................................................................................................................................68 C10. METAL ROOFING................................................................................................................................68 C10.1 General ..............................................................................................................................................68 C10.2 Execution of work ..............................................................................................................................69 C10.3 Joints..................................................................................................................................................69 C10.4 Capping, flashings and other hardware.............................................................................................69 C10.5 Damage and performance .................................................................................................................69 C10.5 QA/QC template ................................................................................................................................69 C11. POLYMER-TYPE CHAMBERS ..................................................................................................................70 C11.1 Approved chambers...........................................................................................................................70 C11.2 Foundation.........................................................................................................................................70 C11.3 Penetrations.......................................................................................................................................70 C11.4 Infiltration performance ....................................................................................................................70 C11.5 Backfill................................................................................................................................................70 C11.6 QA/QC template ................................................................................................................................70 10. TESTING ............................................................................................................................................71 10.1 ROADING AND DEVELOPMENT....................................................................................................................71 10.2 BACKFILL COMPACTION TESTING.................................................................................................................71 10.3 INSTALLATION OF POLYETHYLENE PIPE..........................................................................................................71 10.4 STEEL PIPE WELD BAND, SOCKET AND SPIGOT JOINTS – PIPE ≥700MM NB ...........................................................72 10.5 PRESSURE AND LEAKAGE TESTING ...............................................................................................................72 10.5.1 Pipeline testing .................................................................................................................................72 A) Non-pressure pipelines – Field leakage testing ...............................................................................................72 A-1) Low pressure air test .........................................................................................................................................73
  • 8. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 8 of 92 A-2) Hydrostatic test .................................................................................................................................................74 B) Pressure pipelines general requirements – Field hydrostatic pressure testing...............................................74 B-1) Selection of test pressure ..................................................................................................................................75 B-2) Selecting test lengths.........................................................................................................................................75 B-3) Pre-test procedures ...........................................................................................................................................75 B-4) Post-test procedures..........................................................................................................................................76 B-5) Constant pressure test (water loss method) – PVC, DI, GRP, and steel pipelines..............................................78 B-6) Pressure decay test for PE pipe larger than DN200 or longer than 250m .........................................................78 B-7) Pressure rebound test for PE up to DN 200.......................................................................................................80 B-8) Visual test for small pressure pipelines .............................................................................................................80 B-9) Hydrostatic pressure test for PE pressure pipelines ..........................................................................................81 10.5.2 Manhole and chamber (concrete) testing ........................................................................................81 A) Hydrostatic testing of concrete manholes.......................................................................................................81 B) Vacuum test.....................................................................................................................................................82 C) Infiltration test.................................................................................................................................................82 D) Visual check (smoke test) ................................................................................................................................83 10.5.3 Manhole (plastic/GRP material) testing............................................................................................83 10.5.4 Fluid retaining structures (process tanks, reservoirs, etc.)...............................................................83 A) Concrete tanks.................................................................................................................................................83 B) PE, GRP, steel tanks .........................................................................................................................................85 10.6 POTABLE WATER INFRASTRUCTURE DISINFECTION...........................................................................................85 10.7 CONCRETE – BUILDINGS AND STRUCTURES ....................................................................................................85 10.8 SHOTCRETE............................................................................................................................................85 10.9 MASONRY.............................................................................................................................................85 10.10 TESTING OF PLUMBING INSTALLATIONS ......................................................................................................85 10.11 TIMBER MOISTURE CONTENT ...................................................................................................................86 10.12 DIRECT CURRENT VOLTAGE GRADIENT (DCVG) COATING DEFECT SURVEY FOR NEW STEEL PIPELINES .........................86 10.12.1 DCVG survey types..........................................................................................................................86 10.12.2 Minimum qualifications..................................................................................................................86 10.12.3 Testing.............................................................................................................................................86 10.12.3.1 Visual inspection & preliminary tests........................................................................................................86 10.12.3.2 Method......................................................................................................................................................86 10.12.4 DCVG survey procedures ................................................................................................................89 10.12.5 Acceptance criteria .........................................................................................................................90 10.12.6 Re-test following defect correction ................................................................................................90 10.12.7 Report .............................................................................................................................................92 10.13 MORTAR REHABILITATION (LINING REPAIR).................................................................................................92
  • 9. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 9 of 92 Definitions Assets Water and wastewater infrastructure owned and operated by Watercare. As specified In reference to quality control check sheet templates, an action of audit to be undertaken if specified by the designer or terms of the contract. Brownfields A land area that has existing or legacy infrastructure, or land that has been polluted. Backfill To refill an excavation created during construction for the installation of pipework, foundations etc. Competent person A person who is qualified because of a specific knowledge, training and applicable experience that is familiar with the Health and Safety at Work Act and conversant in identifying and taking corrective action to potential dangers in the workplace. Controlling authority Person(s) in a position of responsibility that is authorised to make a decision on changes, provide access and provide direction. Embankment An rise above the immediate surrounding land to redirect overland flows, or prevent flooding, or a raised bank to carry roads or railways across low-laying areas. Engineer In reference to quality control check sheet templates, a suitably qualified and experienced person to witness and sign-off on the quality and compliance of the work being audited. The quality control checks do not relieve the requirement for producer statements to be signed by a suitable engineering professional attesting that the works have been constructed in accordance with this construction Standard. ESF Watercare’s engineering standards framework is the single point of access for current standards that allows engineering work to comply with the requirements under the Watercare Bylaw. Equipotential bonding Equalising the electrical potential between an electrical connection and a grounding electrode to metal conductors, such as steel pipes that could become conductive. Fill Human created debris discovered within an excavation. Greenfields A land area that has no prior infrastructure development and is unpolluted. Hazard Potential source of harm. Infrastructure Facilities in an operational capacity that is managed by a controlling authority. Risk Combination of the probability of the harm caused by a hazard and the impact or severity that may result.
  • 10. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 10 of 92 Specific drawings Drawings created to inform specific construction requirements from design basis that are not captured by the standards drawings. Utility A public agency, organisation or entity that is licensed to operate and maintain infrastructure for a public service.
  • 11. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 11 of 92 1. Introduction 1.1 Purpose and Scope This standard has been developed to provide the minimum standard of civil construction work acceptable to Watercare. Additional clauses must be added to contracts where specific site constraints exist. This general civil construction document must be supplemented with standards applicable to the specific operational area (see Section 2). The content of this standard may not be changed or amended. Equivalent or alternatives may only be used on written approval from Watercare. Construction work shall be completed by persons competent in their work possessing a minimum skill and competency level required from this standard. 1.2 Applicability This standard applies to all civil construction work for infrastructure delivered by, or vested to, Watercare. The level of workmanship and quality shall be demonstrated to meet this standard. 1.3 ‘Must’ versus ‘Shall’ versus ‘Will’ Where the verbs must, shall and will (or its past tense forms) are used they describe a requirement for compliance with the statement in which it is used. ‘Shall’ and ‘must’ expresses a mandatory condition or action. ‘Will’ is used to prescribe a performance outcome or intent. 2. Standard documents overview 2.1 Relationship of Watercare standards Watercare standards comprise codes of practices, design standards, standard design drawings, construction standards, and asset and material standards. The Watercare standards sets are requirements additional to nominated national standards, international standards and industry best practice to meet, and in some cases exceed legislative requirements, to accomplish long term operability and good asset management practices to benefit our customers. The interface of these standards with each other and the project specifications are as follows: 2.1.1 Design standards The design standard sets a level of design for particular types of infrastructure based on operational area and associated risk. The design standards provide the minimum criteria for: • Establishing standard design drawings • Interface design between standard drawings and specific design • Establishing the correct sizing of components to meet the baseline parameters of the standard drawings • The basis for developing tailored designs 2.1.2 Design drawings The standard design drawings support the requirements of the design standard. Minimum and maximum criteria are set, and specific standard details are shown. 2.1.3 Asset and material standards The asset standards describe the requirements for asset creation, asset numbering, asset capture, production of manuals and operational documentation. Material standards describe the minimum compliance requirements of materials supplied for asset acceptance. Often selected materials will have limitations of use and requirements specific to the operating environment and infrastructure classification. Section 6 describes
  • 12. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 12 of 92 the minimum requirements applicable to this standard. Additional requirements may be specified based on the specific design. 2.1.4 Construction standards Construction standards prescribe the methods and requirements for workmanship to be employed when constructing works in accordance with the design requirements, standard drawings and bespoke designs. To achieve the best outcome the construction requirements focusses on proven methods and best practice to ensure quality is maintained to achieve the design life of infrastructure and that maintainability, health and safety and environmental requirements are met. Where construction standards are used or referred to in contracts they form part of the specification of the contract. 2.1.5 Project specific specification These specifications identify site/project specific requirements that are not covered by the normative construction standards or standard design drawings identified during specific design. 2.2 Design build projects Design build projects shall follow the minimum requirements set out in the standard documents for design and construction. 3. Quality control and quality assurance 3.1 Auditing during construction A construction management plan shall identify the quality control points. This standard includes a number of quality control/assurance templates that highlight key compliance checks to be carried out during construction. These quality control templates shall be completed as part of the construction work together with any project specific record keeping requirements for Watercare. The templates provided are the minimum checks that need to be completed and in some instances are required to be completed more than once depending on the type of installation. See Section 4. 3.2 Change orders affecting quality Any change orders for the works shall not compromise quality, safety and regulatory requirements. Any proposed change shall be evaluated against the applicable standard and be demonstrated to comply with the applicable certification and proof of quality documentation. 4. General engineering document submittal requirements All construction work shall have an accepted construction management plan before any work can commence. This document shall identify the overall planning, coordination and control of the construction activities from start to finish. 4.1 Quality control templates The completed quality control or quality assurance sheets shall be provided during the identified stages in the construction management plan. All the applicable quality controls shall be completed and signed-off before Watercare will accept the assets. Items noted as “required” on the QA/QC sheets must be provided or completed and items noted “As specified” is the quantity or requirements that are specified in the particular clauses of construction or referenced standard (whichever takes priority). Certification blocks that are greyed out with “N/A” defines that the item does not apply to the particular party for certification, or that there are no documentation required for the item.
  • 13. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 13 of 92 The QA/QC templates shall be certified to confirm that all actions have been completed by each individual. Refer to Watercare’s compliance policy for work certification to be delivered. 4.2 Documents for commissioning or livening of civil structures The prerequisite for construction work that requires progressive commissioning or livening is to provide sufficient supporting documentation for the safe and effective operation of the parts. Pre-commissioning test results shall be signed-off before commissioning commences. Refer to Watercare Code of Practice for commissioning COP-03. At completion of the construction work the following minimum documentation is required in its final format for handover to Watercare: • Post construction residual risk register • Operation and maintenance manual • As-built drawings (AutoCAD) and survey data • Assets certificates • Material compliance certificates • Engineering producer statements • Construction completion report • Commissioning documentation • Quality control certificates • Compliance certificate (CS3) Specific details of the content of the above documents and templates are available from Watercare’s Data and Asset Information standard, Material supply standard and CAD manual. Note – The above listed documents are required for general civil construction works. Where specific infrastructure is constructed and this standard is supplemented by the specific standard associated with a component, the additional requirements are provided in the specific standard. 5. Referenced standards 5.1 Standards list This standard must be read in conjunction with the Watercare, national and international standards listed below. Where conflict or ambiguity exists this standard shall take precedence. Where there is conflict between referenced standards, the higher level of standard shall take precedence. 5.1.1 Watercare standards ME - General mechanical construction standard MS - Material supply standard 7363 - Watercare CAD manual AI - Data and Asset Information standard HSE – Standard Health and Safety and Environmental practices DW05 - Access structure drawings for wastewater infrastructure DW06 - Access structure drawings for water infrastructure DW07 - Access structures general drawings for public and non-public areas DW08 - Pipelines for wastewater greater than 300mm diameter
  • 14. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 14 of 92 DW09 - Wastewater manhole drawing set for pipelines 375mm and greater DW10 - pipelines for water greater than 250mm diameter drawing set DW11 - Valve chamber detail drawings for transmission water DW12 - Water stand-alone sampling and rainfall metering DW23 - Cathodic protection mechanical and civil detail drawings COP-03 Code of Practice for commissioning COP-04 Code of Practice for disinfection of water systems 5.1.2 National and international standards Earthworks and roading NZS4402 Methods of testing soils for civil engineering purposes AS1289.6.9.1 Methods for testing soils for engineering purposes – Soil strength and consolidation test – Determination of stiffness of soil – Clegg impact value Approved Code of Practice HSNOCOP 55 Storage of Explosives BS 5930 Code of Practice for ground investigations NZTA F2 (New Zealand Transport Agency) – Specification for pipe subsoil drain construction TNZ B/02 (New Zealand Transport Agency) – Specification for construction of unbound granular pavement layers NZTA M1 (New Zealand Transport Agency) – Specification for roading bitumens NZTA M10 (New Zealand Transport Agency) – Specification for dense graded and stone mastic asphalts Pipe and duct laying AS/NZS 2566 Buried flexible pipelines, Part 2: Installation AS/NZS 2032 Installation of PVC pipe systems AS/NZS 2033 Installation of polyethylene pipe systems AS/NZS 4130 Polyethylene (PE) pipes for pressure applications POP001 Electrofusion jointing of PE pipes and fittings for pressure applications POP003 Butt fusion jointing of PE pipes and fittings – recommended parameters POP005 Packaging, handling and storage of polyethylene pipes and fittings AWWA C209 Cold-applied tape coatings for steel water pipe, special sections, connections and fittings Pipe lining ISO 11298 Plastic piping systems for renovation of underground water supply systems Part 1 – General Part 2 – Lining with continuous pipes Part 3 – Lining with close fit pipes AS/NZS 1516 The cement mortar lining of pipes in-situ AS1012 part 24 Methods of testing concrete – Determination of the tensile bond strength of concrete – Repairs and strengthening systems Concrete AS/NZS 1554 part 3 Welding of reinforcing steel NZS 3104 Specification for concrete production NZS 3109 Concrete construction NZS 3111 Methods of test for water and aggregate for concrete NZS 3112 Methods of test for concrete Part 1 Tests relating to fresh concrete Part 2 Tests relating to the determination of strength of concrete Part 3 Tests on hardened concrete other than strength Part 4 Tests relating to grout NZS 3114 Specification for concrete surface finishes NZS 3121 Specification for water and aggregate for concrete NZS 3152 Specification for the manufacture and use of structural and insulating lightweight concrete AS/NZS 4671 Steel reinforcing materials
  • 15. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 15 of 92 AS/NZS 4672 part 1 and part 2 Steel pre-stressing materials AS/NZS 3679 part 1 Structural steel – Hot-rolled bars and sections Formwork and temporary works AS 3610 Formwork for concrete AS/NZS 4994.4 Temporary edge protection – Part 4 Perimeter protection screens AS/NZS 5131 Structural steelwork – Fabrication and Erection Painting BS5252 Framework for colour co-ordination for building purposes ASTM D-610-08 Method of evaluating degree of rusting on painted steel surfaces AS/NZS 2311 Guide to the painting of buildings AS/NZS 2312 part 1 Guidelines for the protection of iron and steel against exterior atmospheric corrosion Steel Structures Painting Council (SSPC) Painting manual Volume 1: Good painting practice Volume 2: Systems and specifications Demolition AS2601 Demolition of structures Masonry NZS 4210 Masonry construction: materials and workmanship AS 1316 Masonry cement AS/NZS 2699 part 1 and 2 Built-in components for masonry construction AS/NZS 2904 Damp-proof courses and flashings New Zealand Building Code (NZBC) Plumbing AS/NZS 2845 Water Supply – Backflow prevention devices – Materials, design and performance requirements NZS 4503 Hand operated firefighting equipment AS/NZS 1221 Fire hose reels NZS 7643 Installation of uPVC pipe systems AS/NZS 1477 PVC pipes for pressure applications AS/NZS 3879 Solvent cements and priming fluids for PVC (PVC-U and PVC-M) and ABS pipes and fittings BS 143 and 1256 Threaded pipe fittings in malleable cast iron and cast copper alloy BS EN 877 + A1 Cast iron pipes and fittings, their joints and accessories for the evacuation of water from buildings. Requirements, test methods and quality assurance BS EN 12502-3 Galvanised coatings NZS/BS 1387 Steel tubes for threading to BS21 pipe threads New Zealand Building Code (NZBC) Carpentry AS/NZS 1748 Timber - Stress Graded – Product Requirements for mechanically stress graded timber NZS 3604 Timber Framed Buildings NZS 3602 Timber and Wood-based Products for use in Building New Zealand Building Code (NZBC) Metal roofing New Zealand Building Code NZBC E2/AS1 External moisture 4.0 Flashings 5.0 Roof/wall junctions 6.0 Parapets 8.0 Roof claddings 8.1 General 8.4 Profiled metal AS/NZS 4534 Zinc and zinc/aluminium-alloy coatings on steel wire NZ Metal Roofing Manufacturers Inc: NZ metal roofing & wall cladding code of practice NZS 3604 Timber framed buildings
  • 16. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 16 of 92 6. Materials 6.1 Material standards Materials shall include all equipment, machinery, components or products used to complete the works. All materials necessary for the work shall be supplied in accordance with Watercare’s material standards. Materials shall be new and suitable for their intended purpose and performance requirements. Machinery and equipment shall be in a good maintained condition and safe. 6.2 Recycled and reused materials Recycled material and material reuse is not accepted unless specifically approved by Watercare. 7. Health and Safety All work shall be conducted in accordance with the requirements of the Health and Safety at Work Act 2015. Watercare requires that all contractors undergo a Health and Safety induction programme provided by Watercare prior to any work progressing. Health and safety is the responsibility of every person. The minimum health and safety requirements set out by Watercare must be adhered to and the documentation and procedures must be of an acceptable standard: • Describe the processes to assure compliance with systems, good practice and legislation. • Provide information to demonstrate that the Health and Safety Management System is capable of managing specific hazards and meeting Watercare minimum requirements. Regulations, approved codes of practice and industry standards or guidelines should be referenced as the basis for hazard controls. • Provide a Health and Safety Management Plan which addresses controls and unique high risk activities or components of the work. • Demonstrate the proposed risk controls are adequate and identify alternatives to further reduce risk. Where administrative controls are used, it must be demonstrated that these are sufficient, robust and how they will be properly managed. • Provide the names of Health and Safety staff and their responsibilities. • Verify that all workers have received adequate training for managing the hazards and risks and undertaking the work safely. • Conduct and record site specific inductions. • Where work is on an existing Watercare facility or asset an Access Authority is required before work can start. Refer to Watercare’s Standard for Health and Safety and Environmental practice (HSE) for a more detailed breakdown of requirements. 8. Asset capture Asset information shall be progressively captured and supplied in accordance with the requirements of Watercare’s data and asset information standards.
  • 17. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 17 of 92 9. Civil construction Work in public areas and road reserve Work in the road reserve shall comply with the New Zealand Code of Practice for working in the road (NZCOP), and the specific requirements of the Auckland Transport Code of Practice (ATCOP). Work in any public area shall require prior written approval by the controlling authority. All requirements for working in the road such as corridor access request (CAR) and traffic management plan(s) (TMP) shall be implemented and maintained. Any person employed to carry out traffic management duties shall hold approved qualifications at National Certificate Level for road opening operations, supervision and traffic management. Work in private property Written confirmation from the private property owner or controlling authority shall be obtained before work commences in any private property. Locations of access ways and fill areas on property(ies) shall be arranged under the entry agreement with the owner of the property. Work in private property shall minimise inconvenience to the occupiers. Any damage by the contractor must be rectified immediately at the contractor’s expense. C1. Site roading This section covers access driveways and areas of paving associated with Watercare facility sites. It does not cover major earthworks or construction of roads that will be heavily trafficked or are in the road reserve. Under these circumstances the Auckland Transport Code of Practice (ATCOP) or New Zealand Transport Agency (NZTA) requirements shall be the default requirement. C1.1 General Construction of site roading shall comply with the NZTA listed TNZ or NZTA specifications as amended by this standard unless shown otherwise on the specific drawings. C1.2 Paving subgrade preparation a) Excavation practices shall comply with Section C2 of this standard. b) The sub-grade shall be backfilled capable of sustaining minimum 110 kPa in the long term without subsidence. The cross-fall shall be finished to the level shown on the drawings. C1.3 Subsoil drains a) Subsoil drains shall be constructed in accordance with NZTA F2. b) Drains shall be of minimum 300mm width with a depth to invert between 250mm to 500mm. c) All drains shall have outlets into cesspits or other stormwater drainage structures. d) Stormwater drains shall not be connected or directed to the wastewater system. e) Filter material shall be scoria chip graded 20 to 7. f) PVC pipes must not be used. C1.4 Basecourse and sub-base a) Sub-base and basecourse shall be constructed in accordance with TNZ B/02. b) Sub-base aggregate shall be GAP 65 spread evenly over the full formation area and compacted to a minimum thickness of 200mm. c) The base course shall be AP40 crushed aggregate to a minimum finished thickness of 100mm. C1.5 Asphaltic concrete a) Asphaltic concrete shall be supplied in accordance with NZTA M10, mix designation DG7. b) Bitumen shall be NZTA M1 approved with an 80-100 penetration grade. c) Construction shall be in accordance with NZTA M10. Layer thickness shall be 30mm. d) The asphaltic concrete shall have a well compacted dense surface, uniformly graded and free from irregularities. There shall be no area where water will pond.
  • 18. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 18 of 92 C1.6 Kerbing Kerbs shall be of minimum 17.5 MPa precast concrete or alternatively cast in situ concrete to a profile that matches existing kerbs or as specified on the specific drawings. C1.7 Stormwater drainage a) Precast cesspits shall be constructed using minimum 25 MPa grade concrete. Cesspits shall be watertight and support the grating at grade. b) The grating and frame shall be standard heavy duty non-roc pattern cast iron, set in concrete. Unless otherwise noted, outlets shall be trapped. c) Gully traps where required shall be compliant with New Zealand standards. d) Unless the material is noted on the specific drawings, pipe and fittings will be selected from concrete, glazed earthenware, polyethylene or uPVC that shall comply with Watercare’s material standards and constructed in accordance with Section C3 of this standard. e) Where stormwater is connected outside the site the construction shall comply with the Auckland Council Stormwater Code of Practice. C1.8 QA/QC template Quality control shall be demonstrated to meet the testing frequency within the production tolerances as set out in NZTA M10. Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Asphalt grading DG7 grade, NZTA M10, Table 3.2 Required Required As specified 2 Binder content Quality control sheet supplied in compliance with Table 1 of TM6003 (Explanatory notes to NZTA M1) Required Required As specified 3 Maximum specific gravity Within limitations set by Table 9.2 of NZTA M10 Required Required As specified Sign-off C2. Earthworks This section covers site clearing, removal and stockpiling of materials, bulk and detail excavation and backfilling for general civil construction works. C2.1 General a) Safe excavation practices shall be followed in accordance with the WorkSafe NZ: Approved Code of Practice for Safety in Excavations and Shafts for Foundations. b) Work shall be carried out in accordance with the applicable resource consents and environmental compliance requirements. c) Finished surfaces shall be formed and set out to the levels as shown on the specific drawings and be free of depressions and loose materials. d) Refer to Watercare Health and Safety and Environmental practices standard (HSE) for discovery protocols or archaeological, anthropological and antiquarian discoveries. C2.2 Site preparation a) Suitable temporary fencing and signage shall be erected that will control overall access to the site as well as entry into specific excavation areas as necessary for the protection of the public. b) The trimming or temporary relocation of trees or shrubs will be undertaken with the consent of the owner of the vegetation. c) Vegetation that requires protection shall be fenced off beyond its drip-line or as otherwise prescribed by the consenting authority prior to earthworks commencing in the vicinity. d) All cleared material shall be removed from the site. Refer to section C2.5 for any stockpile requirements. e) Tree stumps shall be completely removed. Hollows formed by the stump removal shall be backfilled and compacted level with the surrounding area.
  • 19. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 19 of 92 C2.3 Geotechnical investigations a) In some instances Watercare may provide geotechnical site investigation reports or a geotechnical baseline report (GBR). No responsibility is accepted for its accuracy or relevance. This information shall not be considered as complete and shall be supplemented as necessary for the site specific activities. b) All additional investigation locations shall be surveyed and immediately after the investigations are completed backfilled and sealed. c) All additional geotechnical information obtained shall be uploaded to the Auckland Geotechnical Database, at the following location: (https://agd.projectorbit.com/) C2.4 Topsoil stripping a) Topsoil shall be stripped from all areas to be excavated, backfilled or otherwise disturbed as part of the construction works. b) The topsoil shall be stockpiled in an appropriate area clear of the works site activities. c) The depth of topsoil stripped shall be: • At least 300 mm in farmland, residential property or other cultivated areas, or • At least 150 mm elsewhere, or • The full depth of topsoil when less than the above depths exist. • Completely removed from embankments. C2.5 Stockpiling a) Unless required by the conditions of consent or specific requirements, stockpiles shall be held at the site. b) Different material types shall be excavated and stockpiled separately. c) Stockpiles shall be safe and stable with steep faces that allows maximum drainage. d) Silt barriers shall be installed around stockpiles with suitable drainage. e) Stockpiles shall be covered with a suitable geotextile to prevent erosion or covered with grass of minimum 90% covering from a suitable seed mix. f) Materials unsuitable for reuse shall be removed from site and disposed to an appropriate tip site. g) Material inappropriately stockpiled that has become unsuitable for reuse shall be removed and replaced. C2.6 Excavation support and perimeter protection a) Temporary works design shall be undertaken and installed to provide safety for persons working in and around the excavation that complies with Health and Safety regulations. b) The design shall be undertaken (CS1) or certified (CS2) by a Chartered Professional Engineer registered with CPEC for the relevant practice area. c) The temporary works design shall allow for the safe removal of the supports at completion of the works. In exceptional cases where the removal of temporary support poses a risk to adjacent property or structures the temporary works shall be incorporated into the permanent work on prior approval of Watercare. C2.7 Excavation general a) Any excavation work that is notifiable under the Health and Safety at Work Act shall be lodged with WorkSafe New Zealand. Copies of notifications shall be supplied to Watercare. b) Current services plans from all utility controlling authorities shall be obtained and the services located and marked on site. Utility service providers shall be notified in writing of any intention to excavate within the vicinity. c) Unless otherwise shown on the specific drawings no excavation shall be closer than 500mm to any other utility service or any special backfilling material for that utility. For work close to existing Watercare assets the Auckland Council Water and Wastewater Bylaw shall be followed. d) The ground shall be excavated to the minimum depths necessary for the construction. Deeper excavation may be required to secure a firm foundation. The extra depth shall be backfilled either with concrete or an approved hardfill compacted as specified by the designer. e) Foundations shall be prepared with any fissures cleaned and backfilled with all loose materials removed. C2.8 Water in excavations a) Excavations shall be kept free of water during construction with all practicable steps undertaken to prevent water from entering the excavation.
  • 20. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 20 of 92 b) Water discharged from excavations shall be disposed of in a consented manner. All pipework, sub-drains and sumps shall be installed and the pumping plant operated and maintained as necessary to deliver and maintain the excavation free from water. c) Temporary sub-drains or sumps will only be allowed under any permanent work if essential to keep the excavation clear of water. Temporary sub-drains and sumps shall be blocked off and backfilled with concrete until watertight when no longer required. d) The construction methodology shall ensure there is no risk of hydrostatic uplift or ground subsidence as a consequence of the works. e) De-watering consents may be required and shall be adhered to. C2.9 Excavation for trenches a) The width and depth of trenches for pipelines shall be to exact dimensions. b) Additional excavation is permitted at connections and joints to allow safe and efficient working areas when making connections. Where specific design of the trench limits the width between soil faces the excavation shall not exceed the given dimensions. c) Where trenches are constructed in an embankment the stability and integrity of the embankment shall not be compromised. C2.10 Excavation for structures a) Structures include underground chambers, wells, anchor blocks, permanent piles, concrete bases and any other building requiring a ground foundation. The excavation shall be to the lines and levels on the specific drawings. b) The bottom of the excavation or load bearing area shall be of undisturbed material graded and trimmed, or as otherwise specifically designed, to levels on the specific drawings. C2.11 Excavation by hydro-vacuum excavation a) Hydro-vacuum excavation may only be used in small localised areas as an alternative to hand excavation. b) The excavation shall be directed away from bearing surfaces of existing structures to ensure the structural purpose and integrity of the existing structures is not compromised. c) The excavation shall be to a level above the required lines and levels of the design. Hand excavation or mechanical plant shall be used to finish the excavation to the required dimensions. d) The hydrojet or wand shall never remain motionless and may not advance ahead of the vacuum unit so as to cause flooding of the excavation area or washout of adjacent utility service bedding. e) The maximum water pressure for straight nozzles shall be 100bar and for spinning nozzles 200bar. Pressure shall be monitored and the water supply fitted with an emergency shut-off at the wand as well as at the truck connection. f) The hydro-vacuum equipment and operators shall be protected by equipotential bonding. Hydro excavation in the vicinity of energized plant or damaged cables shall be excavated with the infrastructure isolated and where practical de-energised. g) The excavation shall be screened to prevent any flying debris causing harm or damage. C2.12 Excavation by explosive blasting a) Explosive blasting works shall be notified to WorkSafe NZ. A hazard and risk assessment shall be completed and reviewed by Watercare. b) Blasting shall be carried out by the NZQA certificated construction blaster (appropriate level for activity) responsible for the blasting work. c) Storage and handling of explosives shall comply with the Approved Code of Practice HSNOCOP 55 Storage of Explosives. Only daily requirements shall be held on site. d) All charges shall be screened to prevent any flying debris and all necessary steps shall be taken to warn traffic, workers, nearby residents, and the public when shots are about to be fired. e) Evidence shall be provided that the amplitude of ground vibration due to any blast does not to exceed 0.25 mm when measured at a distance of 150m from the seat of the blast. C2.13 Excavation material classification a) Common material: Common excavation shall include material with plastic properties, un-cemented granular materials and slightly cemented materials, such as earth, clay, silt, sand, gravel, peat, sludge and shall include isolated boulders less than 300mm diameter and pockets of strongly cemented material of less than 0.2 m³ per 1 m³ in volume. The soil strength in this category is 25 kPa to 100 kPa with the standard penetration test (SPT) or N value 3 to 20.
  • 21. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 21 of 92 b) Hard ground: Hard ground excavation shall include cemented material such as: sandstone, mudstone, Parnell grit, breccia, volcanic tuff deposits which exhibit strengths ranging from low to high and which require more effort to excavate than common material but which is capable of being excavated with a modern hydraulic bucket in good condition. The soil strength in this category is 100 kPa to 200 kPa with the standard penetration test (SPT) or N value 20 to 49. c) Loose Rock: Loose boulders are greater than 300mm in diameter and with ratio greater than 0.2 m³ per 1 m³ to hard ground or common material. Loose rock also includes intact rock with unconfined compressive strength (UCS) of 1 to 50 MPa that can be effectively broken by rock breakers or loosened by hydraulic bucket. d) Rock: Rock shall be limited to sound, in-situ basalt, greywacke, or argillite, which requires the use of large efficient rock breakers or explosives to excavate. N value is 50 or greater. The unconfined compressive strength (UCS) of intact rock is greater than 50 MPa for this material class. e) Fill: Fill material may be of various grade or material type and is typically found in brownfield areas. The composition and integrity of fill material found other than described in the geotechnical report, shall be referred to Watercare. C2.14 Backfill and fill in general a) Prior to backfilling all forms and debris shall be removed from the excavation. Temporary support works and timbering shall be removed progressively. b) Backfill material capable of compaction to this standard or as otherwise required by the specific drawings shall be used for backfilling. c) Excavated material unsuitable for backfill shall be disposed of as surplus material. d) Suitable backfill material shall be: • Clean fill free of organic matter • Free from hazardous substances or contaminants • Plastic index less than 30 • Capable of achieving the compaction criteria in Section C2.15 e) The backfill placed within 300mm of any structure shall be ordinary surround material (refer section C2.16) unless otherwise specified. C2.15 General compaction of backfill a) Backfill shall be placed in layers less than 230 mm thick in accordance with table C2-1, unless specified otherwise for a specific pipe material. Table C2-1 Compaction requirements Also see requirements for specific installation material that may vary from the below table. Application requiring compacted backfill Modified maximum dry density % Building foundations beneath hardfill 95 Backfill behind walls or chambers 90 Areas of fill in non-trafficked open ground 90 b) Care must be exercised during placing and compacting to prevent displacement or damage of infrastructure and in such a manner as to avoid uneven loading. c) Hand rammers must be used where there is a risk of displacement or damage to infrastructure. d) Hardfill within 300mm of the underside of a concrete floor slab shall be placed and compacted in layers less than 150mm in thickness. e) Hardfill within 100mm of the underside of a concrete floor slab shall be less than AP 20 in size. C2.16 Backfill material classification a) Ordinary backfill: Material free of organic matter, hazardous contaminants and any other substance which prevents satisfactory placing and compaction. b) Ordinary surround material: Ordinary backfill as above but also free of clay lumps and stones retained on a 75mm sieve and not more than 10% shall be stones retained on a 25mm sieve. c) Granular surround material: This shall be imported material, or site excavated crushed and graded stone, graded as for ordinary surround material. Coarse sand or fine scoria may only be used when specified.
  • 22. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 22 of 92 d) Hardfill: Hardfill shall be of granular nature, free of organic matter, hazardous contaminants or other deleterious material. Hardfill shall be approved before placing and may include but is not limited to: Run of pit (ROP), scoria, concrete washings, reject base course and natural gravel. e) Refer to the specific requirements for pipe materials under the pipe and duct laying sections in this standard under section C3. C2.17 Surface reinstatement a) Unless different surface reinstatement is specified in part or whole, the surface of all disturbed areas shall be reinstated to its original condition and matching adjoining surfaces. b) Landowner approval of the reinstatement shall be obtained. c) Roading and footpath reinstatement shall be to the controlling authority’s specification. C2.18 Top soil and grass reinstatement a) Areas to be grassed shall be graded to provide a finished level flush with kerbs and mowing strips or to levels shown on the specific drawings. b) Mowing strips shall be 300 mm wide constructed from 17.5 MPa grade concrete with joints at 2 m intervals. The strip shall be finished off to give a straight even edge and smooth top, level with the final grade of the grassed area. c) Areas to receive grass shall be uniformly relieved by cultivation and ripping. Areas that do not have at least 100 mm of topsoil shall first be uniformly and lightly compacted and evenly graded to 100 mm below finished grade before spreading 100 mm of weed free topsoil. d) Fertiliser (containing three parts superphosphate and one part of sulphate of ammonia) shall be spread at the rate of 50 g/m2 over all areas to be grassed, and the topsoil cultivated to a minimum depth of 75 mm. All sticks, stones, and other debris shall be removed and the area lightly rolled. e) Unless otherwise specified grass seed containing a high proportion of perennial rye shall be sown in suitable weather conditions as prescribed by the supplier at the rate of 35 g/m² and hand raked into the top 20mm of soil. f) Maintenance of the grassed area shall continue until minimum 90% coverage is obtained in all areas. During this period the area shall be watered, weeded, re-sown, rolled and mown as often as necessary. Any undue settlement shall be made good. Once the coverage has been obtained a further application of fertiliser at the rate of 50 g/m² shall be applied. C2.19 Surplus material Surplus material remaining after completion of the work or material removed during construction that will not be reused shall be disposed off-site to an appropriate tip site. C2.20 Record keeping The following records shall be maintained during the work: • Extent of excavation and backfill areas • Type and quantity of excavated and backfill material • Compaction records and the location of tests • Material quantity removed from site with tip site dockets C2.21 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Services located Mark-outs and plans Required Required N/A 2 Clearing and establishment As consented, accepted construction plan N/A Required As specified 3 Topsoil Identified, graded, stored N/A Required As specified 4 Geotechnical investigation Recorded, surveyed, uploaded to AGD, restored Required Required Required 5 WorksafeNZ notification Notifiable works – response from Worksafe NZ Required Required Required
  • 23. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 23 of 92 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 6 Excavation Material classification, test records and quantity records Required Required N/A 7 Temporary support design CS1, or PS1 if required Required Required N/A 8 Line and level correct (survey), clear of debris and defects Required Required As specified 9 Backfill Temporary support removal plan Required Required N/A 10 Backfill material grading N/A Required Required 11 Plastic index <30. NATA/IANZ test lab results Required Required N/A 12 Compaction test. NZS 4402, Test 5.1.2 and 5.1.4 – NATA/IANZ test lab results, or Clegg hammer impact tests to AS1289.6.9.1 Required Required N/A 13 Compaction test location records Required Required N/A 14 Reinstatement Topsoil replaced to 100mm depth, clear of stones and debris, 90% grass cover N/A Required Required 15 Controlling authority(ies) sign-off Required Required Required 16 Surplus material removed Site inspected. Tip facility records provided Required Required N/A Sign-off C3. Pipe and duct laying a) This section covers the general civil construction of underground pipelines and ducting for Watercare’s services. b) This section does not include mechanical construction requirements for particular requirements of welding, flanges and fittings. Refer to Watercare’s General Mechanical construction standard. c) Where ‘pipe’ or ‘piping’ is referred in this section it shall be read to also mean any pipe or conduit for the purpose of ducting. C3.1 General Pipeline construction a) Subsections for specific construction methods shall be read in conjunction with these general requirements b) Pipe shall be transported and handled according to the manufacturer’s requirements for the specific material type to avoid damage. c) Pipe shall be stacked not more than three layers high or as otherwise specified by the manufacturer’s recommendations and without placing excessive loads on the lower layers. Stacks shall be arranged not to place any load on pipe ends. Pipe supports shall not create point loads on the pipe. d) Pipe ends shall be capped. e) Excess pipe (where supplied by Watercare under contract) shall be returned to the specified Watercare storage facility. f) All non-metallic pipelines shall have an accepted tracer wire installed over the entire length of the installation (refer section C3.1.7) with suitable connecting stations where practicable. Additionally pipe installed by open trenched methods shall have an applicable warning strip e.g. “CAUTION – WATER MAIN BELOW” or an approved equivalent of minimum 100mm width at 450mm above the pipe. The service appropriate colour coding shall be to AS/NZS2648: Service Colour Electricity Orange Gas Yellow Water Blue
  • 24. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 24 of 92 Service Colour Communications Green Firefighting* White Sewerage Cream Reclaimed water Purple *applies to dedicated fire lines. Reticulation mains with hydrants installed on them shall be blue. g) Trench bedding and pipe surround shall be progressively inspected as the work continues. Pipe shall not be installed before a new section of bedding has been inspected. h) Open trenches shall not progress more than 75m ahead of completely backfilled and sealed section or as otherwise limited by the controlling authority. i) Flexible pipelines as defined by AS/NZS2566 shall be tested for oval caused by superimposed loads and inappropriate sidewall support. On completion of the pipe installation (for any pipe laying technique) the pipe shall be tested by pigging or laser scanning (where more practical for larger diameters). j) On completion all pipework shall be CCTV inspected for defects, in particular pipe joints and to identify ponding areas for correction in gravity systems. C3.1.1 Position tolerances a) Pipe shall be installed to the line and level required on the specific drawings. The position tolerance for pipe laying at any point along the length of the installation shall be within ±30 mm from the specified design. b) Additionally the following specific allowances apply: • No over vertical (causing upstream ponding) for any wastewater or drainage pipeline. • Horizontal directional drilling (HDD) to a maximum horizontal deviation of 100mm. • Pipe jacking, boring or tunnelling to a maximum horizontal deviation of 100mm. c) Pipe penetrations into any structure shall be to the location and tolerances specified on the specific drawings. C3.1.2 Bedding material, pipe surround and compaction a) Filling of bedding and pipe surround material shall be to the dimensions specified on the standard drawings for the appropriate installation area and service type or as otherwise stated by the design specific drawings. b) Bedding and pipe surround material shall be as specified on the standard drawings or as otherwise stated by the design specific drawings (i.e. earthquake resilient design or rigid pipe as per section C3.9). c) Alternative bedding material may be proposed but requires specific approval (must comply with AS/NZS 2566 for flexible pipe or AS/NZS 3725 for rigid pipe). d) Where there is a risk of soil fines migrating into the trench the affected section shall be lined with geotextile. e) Compaction of the bedding and pipe surround backfill shall be 70% of the density index (95% dry density ratio) for cohesion-less soils for both trafficable and non-trafficable areas and is based on the standard detail. f) Compaction shall be as specified when using an approved alternative. g) Pipe deflection shall comply with the standards for flexible and rigid pipe installation and compared against the calculated short and long term deflection for acceptance. h) For concrete encasement the concrete shall be vibrated into position from one side of the pipe only. The concrete shall have a slump value of 180-200mm. Note – the above requirements are for open trench excavation in competent soils. Where an installation technique other than open excavation is employed the specific requirements are described in the applicable section in this standard. The trench design will be based on geotechnical findings during design investigations. Where it is identified that the geotechnical conditions differ, it must be reported to the designer to review the pipe bedding specification to confirm that there is no risk of subsidence, hydrostatic uplift or any other soil conditions that may compromise the pipeline integrity. C3.1.3 Pipe laying in embankment a) Pipe laying in embankments shall be to the specific design requirements.
  • 25. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 25 of 92 b) Where a trench preparation requires over excavation to be corrected and/or where the embankment material differs in type and compressibility from the design conditions the designer shall specify the corrective action. C3.1.4 Pipelines through structures a) Pipes passing through structures shall be thoroughly cleaned and wrapped with an accepted protective coating to the coating manufacturer’s specification. b) The protective wrapping shall be extended minimum 150mm beyond the face of the structure. The following wrapping types shall apply: • Steel or ductile iron: bituminous or petrolatum based • Plastic to steel, or to ductile iron interface: bituminous c) Hydrophilic water-stop seal shall be applied as required for chambers and manholes to ensure there is no leakage between the pipe and the structure. d) Where puddle flanges are installed the wrapping shall be to the base of the puddle flange on each side, not over it. e) Before the pipe is cast in place and after placing any reinforcing steel the pipe wrapping shall be inspected for any defects. The specific design may require pipework to freely move through a penetration. C3.1.5 Parallel pipeline separation a) Parallel pipelines shall have minimum clearances between pipes and any other services or structure as required by Watercare’s design standards. b) Where pipes of different diameters are placed in parallel the clearance required by the larger service shall be observed. c) In brownfield situations passing an obstruction may require a standard clearance to be reduced. Watercare Operations and the other utility owner must be agreeable to the proposed reduction in clearance. The reduced separation must not: • prevent future maintenance and operation, and • not impact structurally on the pipe or obstruction, and • not be longer than 2m. C3.1.6 Vertical separation from other services a) The minimum vertical separation distances between the pipe and any other services or structure shall be maintained as required by Watercare’s design standards. b) In brownfield situations the minimum clearances as required by the design standard may need to be reduced when unknown structures are encountered. Watercare Operations must be agreeable to the proposed reduction in clearance. The reduced separation must not: • prevent future maintenance and operation, and • not impact structurally on the pipe or obstruction. c) The crossing length must be kept as short as is practicable. C3.1.7 Trace wire installation a) A suitable trace wire system from the Material Supply Standard shall be selected, including the proprietary splicing and test point fittings. b) Tracer wire shall be secured to the pipe at three metre intervals. c) When placing a tapping band on the pipe, ensure that the tracer wire is not placed between the pipe and tapping band and provide adequate slack over the fitting. The wire shall be protected from excavation works. d) With exception of approved spliced connections the tracer wire shall be continuous from between valve chambers or connection/trace points. e) No breaks or cuts are permitted. f) Spliced or repaired connections to the tracer wire shall be made using proprietary splice fittings. g) The tracer wire shall be secured to the outside of the valve sleeve and brought up to the valve box to a point 100mm below the surface and an additional 500mm of slack in such a manner as not to interfere with the working of the valve or damage the wire.
  • 26. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 26 of 92 h) The main line tracer wire shall follow hydrant laterals up to and back from the hydrant and then continue along the watermain. i) The testing for functionality will only be undertaken after confirmation that the installation has been completed. j) A test certificate shall be supplied to Watercare on the outcome of the test. C3.1.8 QA/QC template Note – Where an installation techniques other than open excavation is employed the specific requirements are described in the following sections. The general requirements set out above also apply to these other techniques. Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Storage and handling Pipe ends capped, Stacked safely, less than 3 high, pipe ends clear N/A Required N/A 2 Pipe inspection Free from damage. Pipe lining cracks restored (as applicable to pipe material) N/A Required Required 3 Trench installation Warning strip installed N/A Required As specified 4 Traceability Non-metallic pipe with tracer wire, continuity test certified Required Required Required 5 Position Requirements of C3.1.1 N/A Required As specified 6 Pipe through structures Protective wrapping 150mm beyond each face N/A Required As specified 7 Material outer protection, wrapping, joint inspection Coating or wrapping completed as required for the specific material. N/A Required As specified 8 Separation Parallel according to table C3-1 N/A Required Required 9 Vertical crossings Min. 150mm, other services load protected N/A Required Required 10 Pipe oval Pipe pigging or bore scanning to be within acceptable design parameters Required Required Review document 11 CCTV CCTV inspection – Reviewed for defects. Lining repairs completed. Required Required Review document 12 Deflection check Pipe tested for deflection after backfill and compaction to AS/NZS2566. Rigid pipe test at manufacture and compared to installation Required Required Required 13 Testing & disinfection Testing requirements for pressure, non-pressure pipe, or sleeve as appropriate. Refer to Section 10 Required Required Review document Sign-off
  • 27. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 27 of 92 C3.2 Pipe jacking, boring or tunnelling and shaft sinking This section shall be read in conjunction with section C3.1. C3.2.1 General a) Contractor’s staff shall be appropriately trained and the day-to-day activities of the tunnelling or jacking operations shall be appropriately managed in accordance with the Health and Safety at Work Act, Mining Operations and Quarrying Operations regulations as well as the implementation requirements of Worksafe NZ’s high hazard unit. b) Refer to Watercare Health and Safety and Environmental practices standard (HSE) for discovery protocols or archaeological, anthropological and antiquarian discoveries. The Contractor will monitor the following features during the works which could be symptomatic of a cave presence: • Reduction in telescope station load • Loss of slurry flows and pump pressures through head • Sudden loss of TBM Thrust cylinder pressure and/or cutter head torque • Potential increase in advance speed • Machine pitch decreasing c) The tunnelling or jacking installation design shall be appropriate for the work and the contractor shall include specific risk mitigation plans for Watercare’s consideration. d) Appropriate storage shall be allocated for excavated material. All excavations, headings and tunnels shall be adequately supported at all times. e) Any removal of water during the work shall not cause subsidence, damage to the works or damage to any other property. Once completed shafts and tunnels shall be watertight with no signs of seepage. Any dewatering consents where required must be adhered to. f) Sufficient ventilation shall be provided at all times during construction. g) The type of tunnelling operation method shall be limited to the internal dimension of the pipe tunnel in accordance with the British Tunnelling Society and the Pipe Jacking Association:
  • 28. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 28 of 92 Table key: Acceptable – undertake assessment of the risks and controls associated with the tunnelling works. Avoid – Requires robust technical assessment to justify the tunnelling technique and deviation from acceptable criteria. Appropriate health and safety controls and risk management shall be in place. Not Acceptable – This technique may not be used under any circumstances. An alternative solution shall be sought.
  • 29. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 29 of 92 C3.2.2 Jacking pits, headings and shafts a) Construction of shafts and chambers required for the works shall be specifically designed to accommodate the tunnelling or jacking method. b) The construction design shall allow for removal and reinstatement as required by this standard. The design shall be provided with CS1 and its implementation by CS4 compliance statements. c) A safe means of access and egress shall be provided. Where any mechanical means is provided, ladder access shall also be provided. d) The base shall be concreted and any segmented joints grouted or annulus filled, refer section C3.2.4. e) Openings in shafts and pits shall only be made after grouting has been completed. All openings shall be engineered and drawings provided. C3.2.3 Installations under roads or other facilities The installation under roads or other facilities must not: • Interfere with the normal operation of the road or facility • Cause any damage, deformation or weakening of the road or facility • Interfere with any other facility or utility service C3.2.4 Over excavation and grouting a) The product pipe shall not be subjected to hydrostatic pressure from the grout or aquifer system during the grouting phase that cannot be withstood by the specified product pipe. b) The contractor shall provide design calculations to show that the anticipated net pressure on the tunnel is less than 2.5 times the critical buckling pressure of the tunnel. c) The grouting process shall not deform the product pipe or dislodge supports and move the pipe from its designed alignment. d) The maximum length between grouting points shall be 30m for augers or jacked pipes and progressive for tunnel boring machines. e) Any gaps between the outside of the pipe wall and the surrounding soil shall be pressure grouted with free flowing filler for the full length of the bore to provide structural support for the tunnel and to seal against groundwater where appropriate for the soil type i.e. competent/self-closing clay soils may not require to be grouted as long as no surface distortion occurs. f) The grout shall have a minimum 100 year life expectancy. C3.2.5 Pipe jacking a) It shall be demonstrated that the jacking loads are less than the maximum loads that the jacking pipe are able to withstand. b) The jacking ram shall transfer load to the pipe through a thrust ring to provide an even load. c) The pipe manufacturer’s permitted draw and angular deflection shall not be exceeded at any pipe joint. d) Cut pipes shall not be jacked. e) Pipe joints shall be true and the jacking load continuously applied to prevent joints from opening when the jacking loads are removed. f) Intermediate jacking pits shall be used to prevent the maximum jacking force being exceeded. The location of the intermediate jacking pits shall be agreed with Watercare in advance. C3.2.6 Micro-tunnelling The micro-tunnelling machine shall be selected in respect of the drive length and soil conditions. Micro- tunnelling shall comply with the above sections. C3.2.7 Reinstatement of jacking pits a) Jacking pits or trenches excavated to install pipe shall be reinstated within seven days of completion of pipe installation operations. b) The order of closing shall be from the tunnelling shield working backwards. The pipe joints in the intermediate jacking pit shall be sealed, the receiving joint face re-packed and the joint closed by jacking the upper-end pipe forward. c) It is not acceptable to form a pipe joint in the intermediate jacking pit with a pipe cut-in.
  • 30. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 30 of 92 C3.2.8 Record keeping The following records shall be maintained during the tunnelling works on a daily basis: a) Daily report: • Progress, time and events • Issues and risks • Special events • Any updated on details for each of the drilling stages - reaming sizes/steps b) Drillers log: • Details for each of the drilling stages - reaming sizes/steps • Drill bit type and size • Torque • Thrust force on pipe • Pump rate and pressure c) Steeling log: • Line and level • Deviation from design C3.2.9 QA/QC template This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Work method statement Accepted to include best practice and regulatory requirements as enforced by Worksafe NZ Required Required Review document 2 Tunnel machine suitability Evaluation against expected soil conditions Required Required N/A 3 Worksafe NZ notification Worksafe NZ certification Required Required Required 4 Tracking system accuracy check Verification to accuracy tolerance per Section C3.1.1 Required Required Review document 5 Construction daily records Section C3.2.8 Required Required As specified 6 Grouting plan Quantity calculation comparison to actual measured Required Required Required 7 Jacking pit/ shaft pit construction CPEng, CS1 and CS4 to meet selected machine requirements Required Required Required Sign-off C3.3 Horizontal directional drilling (HDD) a) This section shall be read in conjunction with section C3.1. b) Contractor’s staff shall be appropriately trained and the day-to-day activities shall be appropriately managed in accordance with the Health and Safety at Work Act and the enforcement requirements of Worksafe NZ’s high hazard unit as appropriate. c) The Contractor shall provide the following items: • Construction and environmental management plan and specifically addressing the risk of frac- outs • Calculations for completing the drilling works and any temporary works • Tracking systems and a description of the system to be used and its appropriateness • Drilling fluid (where required) and cuttings management plan • Contingency plans • Records as per section C3.3.7
  • 31. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 31 of 92 d) The drill string entrance angle shall be between 8 and 20 degrees. e) The drilling activity will be surveyed and include the use of a wire line steering system to guide the direction of drilling. A surface tracking system may be used where necessary or an alternate method(s) to achieve the designed vertical and horizontal alignment. f) Ballast shall be inserted into the product pipe for neutral buoyancy when submerged in drilling mud that could cause uplift. g) The pipe must be sealed at either end with a cap or a plug to prevent water, drilling fluids and other foreign materials from entering the pipe. h) Pipe rollers, skates or other protective devices shall be used to prevent pipe damage during pull-back and also to eliminate ground drag. Recommended reaming diameters are listed in the following table. Table C3.3-1 Recommended reaming diameters Pipe Outside Diameter (mm) Back – Ream Hole Diameters (mm) 63 75 to 100 90 100 to 150 110 150 to 200 160 250 to 300 225 300 to 350 315 350 to 400 ≥ 315 At least 1.5 times pipe OD C3.3.1 Calculations The calculations will confirm as is appropriate for the drilling technique, soil type and site specific activities that the following has been accounted for where appropriate in the installation methodology: a) The bending radii do not exceed allowable limits b) Pre-installation loads including hydrostatic test loads and self-weight spanning between any supporting structures do not exceed allowable limits c) The installation loads shall consider: i. Bending stresses due to radius of curvature and pipe over bend where required ii. Maximum installation force on the product pipe iii. Stresses due to frictional drag that may be caused by specific soil types iv. Stresses due to torsional force v. Hydrostatic load due to ground water where required vi. Earth overburden loads on pipe installed deeper than 3 meters vii. Loads resulting from drilling fluid and/or grouting where used against annular pressure limits viii. Construction installation loadings do not exceed allowable limits of the pipe (such as demonstrating limited pull force on the proposed machine) C3.3.2 Construction plan The following information shall be submitted with respect to the construction plan: a) Type and capacity of drilling rig to be used on the project, including thrust and rotary torque. The drilling rig pull/push capacity should be at least equal to twice the weight of the product to be pulled or the weight of the drilling rod in the hole, whichever is greater b) Type and capacity of mud mixing system c) Access requirements to site d) Drawing of work site indicating the location and footprints of all equipment, location of entry and exit pits and the location of slurry containment pits e) A listing of any specialised support equipment (if applicable), including sucker trucks and/or pumps for mud recycling f) Down-hole tools and their suitability for the expected ground conditions g) Management of groundwater during drilling and grouting processes h) Construction records including: i. Diameter of pilot hole ii. Number and size of pre-reams iii. Back ream rate
  • 32. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 32 of 92 iv. Use of rollers, baskets and side booms to suspend and direct the pipe during pull-back v. Pull in rate vi. The number of sections in which the pipeline is to be installed vii. The drill alignment plan in the form of an electronically generated bore plan viii. Drilled bore logs and any computer output data from steering and tracking systems for each part of the works ix. Grouting type and procedure C3.3.3 Tracking systems The appropriateness of the system shall be confirmed for the site specific conditions with the following details: • Type • Operating range • Degree of accuracy C3.3.4 Drilling fluids and cuttings management plan a) An appropriate drilling fluid shall be used to suit the ground conditions during the pipe installation operations. b) Details of any drilling fluids proposed and the estimated volumes to be used are to be submitted to Watercare before any drilling. Drilling fluids to be used shall be environmentally sound and biodegradable. c) Drilling fluid pressures shall be continually monitored by a down-hole data logger to avoid or minimise hydraulic fracturing or over excavation. Care shall be taken in minimising the loss of drilling fluids onto the ground or the environment. d) If hydraulic fracturing, loss of fluid or no returns are discovered the process shall be halted until the issue is rectified. e) Cuttings and spent drilling fluids shall be disposed of properly and shall comply with the local authority regulations. C3.3.5 Contingency plans Contingency plans must be in compliance with national standards, relevant legislation and resource consent conditions and shall be developed for the following: i. In case of spill or surface seepage (e.g. drilling fluids, hydraulic fluids and spoils), including measures to contain and clean the affected area ii. Recovery method in the case of a stuck drill head iii. The remedial treatment of joints, fractures and any other defects in the strata in the event of drilling fluid loss, cuttings loss or groundwater loss during the drilling, reaming and pipe installation processes iv. Correction of ground heave or subsidence C3.3.6 Grouting Grouting shall be in accordance with section C3.2.4. C3.3.7 Record keeping The following records shall be maintained during the drilling works on a daily basis: d) Daily report: • Progress, time and events • Issues and risks • Special events • Any updated on details for each of the drilling stages - reaming sizes/steps e) Drillers log: • Details for each of the drilling stages - reaming sizes/steps • Drill bit type and size • Torque • Pull/thrust force on pipe • Pump rate and pressure f) Steeling log: • Line and level
  • 33. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 33 of 92 • Deviation from design g) Fluid summary: • Drilling mud volumes, • Viscosity • Weight and density • Sand content • Rheology (PV / YP) • pH • Types and volumes used C3.3.8 QA/QC template This template is in addition to C3.1.8 Quality Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Pre-qualification Work method statement - Accepted to include best practice and regulatory requirements as enforced by Worksafe NZ Required Required Review document 2 HDD plant suitability - Evaluation against expected soil conditions; tool inspection Required Required N/A 3 Construction plan Required Required Review document 4 Pipe load force calculations Required Required Review document 5 Site Setup Worksafe NZ notification Required Required N/A 6 Entry and exit points and angles Required Required Review 7 Pilot Hole Drilling Steering calibration check Required Required Review 8 Pilot bore drill logs – drilling rate Required Required Review 9 Tooling inspection Required Required Review 10 Annular pressure limits set Required Required N/A 11 Pilot hole record - Within allowable tolerance Section C3.1.1 Required Required Review 12 Drill fluid ongoing tests - Test records Required Required N/A 13 Reaming Tooling inspection Required Required N/A 14 Cuttings tracking Required Required N/A 15 Back ream rate calculation - Data logged ream rate corresponds to calculation Required Required Review document 16 Pipe Insertion Review reaming and cleaning logs Required Required Review document 17 Tooling inspection Required Required N/A 18 Insertion loads - Conforms with calculation in item 4 Required Required Review 19 Pipe Testing Gauging record Required Required Review 20 Annulus grouting record (if required) - Measured values compared to calculated quantity. Required Required Review 21 Pipe pull visual inspection - Damage <10% gouge depth Required Required Review 22 Records Provide daily records as per C3.3.7 Required Required Review Sign-off
  • 34. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 34 of 92 C3.4 Installation of polyethylene pipe a) This section shall be read in conjunction with section C3.1. b) Polyethylene may be installed by open trench excavation or horizontal directional drilling. c) The polyethylene pipe suitability shall be confirmed for the type of installation. Where Watercare is supplying the pipe material, installation method shall be appropriate for the pipe material. d) Pipes shall be visually inspected before installation and shall satisfy the requirements listed in the below table. The delivery dockets and pipe inspection reports are to be submitted to Watercare within two working days of the delivery. Table C3.4-1 Visual inspection requirements Condition Requirement Branding The pipe material, size and SDR details on the drawings agree with the pipe branding. Branding shall be to the Watecare material standards. Out of roundness Within testing standard. Reversion The pipe shall not exhibit strong reversion at the pipe ends. Eccentricity Pipe wall thickness measured at any point with Vernier callipers. Surface finish There shall be no extrusion die marks or spider-lines, or evidence of crazing, flaking, indication of disintegration, pitting, or discolouration. Scratches None on the internal surface. External surfaces shall be free from longitudinal or circumferential sharp scratches deeper than 10% of the pipe wall thickness. e) Watercare shall be advised if any of the pipes or fittings delivered to site do not meet the requirements of the visual inspection. f) Fittings and accessories shall be stored in their original containers or suitable protective bins. g) Polyethylene pipe can expand and contract when exposed to temperature changes. Pipes must not be secured by backfilling until this contraction has taken place and branches and end fittings must not be completed until this time. Where pipelines are installed by HDD the pipe stretch shall have recovered and thermal contraction complete before restraining the pipe. h) Anchor blocks shall be installed as specified by the drawings with a protective polythene membrane to prevent damage to the pipe. C3.4.1 Pipe curving a) Where site conditions and practical restraints of bending large diameter pipe allow, small curvatures in the pipe can be achieved by bending of the pipe barrel. b) The bending radius, Rb for such bends shall be greater than the pipe manufacturer’s allowance as defined by the below equation with a 1.25 factor of safety applied. Rb = minimum bending radius (m) M = bending moment (N.m) Sb = allowable bending stress for the pipe material (MPa) E = Short term Modulus of Elasticity (for PE 100 E=950 MPa) I = moment of inertia (m4 ) Do = Mean pipe outside diameter (m) n = Safety factor (1.25)
  • 35. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 35 of 92 c) Bends or manholes (for gravity wastewater, drainage and ducts) shall otherwise be installed. Watercare may consider gravity services to be installed on a curve by specific approval, typically where it can be demonstrated to be the best practicable solution and not cause undue maintenance and access difficulties for operational and future replacement purposes. C3.4.2 Pipe bends and fittings Bends and fittings shall be shop-fabricated by the pipe supplier or by an approved specialist fabricator. Fabrication on site is not permitted. Refer to Watercare’s Material Supply standard. C3.4.3 Pipe jointing a) Jointing shall be by fusion butt welding of the material. Electrofusion couplers, mechanical PE couplers or flanges welded to the pipe shall be used only where specified. b) A Work Method Statement (WMS) shall be supplied for the works being undertaken. The WMS must be approved prior to the work commencing, including pre-qualification test weld work.. c) Refer to Section 10.3 for joint testing requirements and methods. Pipes shall be jointed in accordance with the Plastics Industry Pipe Association (PIPA) POP001 for electrofusion methods and POP003 for butt fusion methods. d) For joints by any other mechanical means the mechanical construction standard shall apply. e) Construction welding shall not proceed until the contractor has proven pre-qualification test welds are ductile for each nominated welder and the pre-qualifications are confirmed by Watercare as being acceptable. f) All construction welding shall be undertaken using the same welding operators, welding machines, plant and welding parameters that produced the acceptable pre-qualification welds. Change or substitution of any plant and/or operator requires a repeat of the pre-qualification weld using the new plant and/or operator. g) If a pre-qualification test weld does not meet the acceptance criteria the contractor shall take corrective actions and submit a non-compliance report (NCR) on its findings and the action taken. The welding parameters shall not be changed without written consent. The contractor shall then prepare and test three additional pre-construction test welds at its cost. h) During construction destructive testing shall be undertaken. The number of welds to be removed shall be one in every 20 welds completed (5%) per pipeline or a minimum of 2 whichever is the greater. i) Construction weld samples shall be taken at random, and wherever possible will be taken from the pull- off side of the butt-welding machine to reduce replacement time. j) Where a construction test weld fails destructive testing refer the below flow chart for quality assurance process.
  • 36. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 36 of 92 Chart C3.4.3-1 Destructive testing QA flow chart k) Hand scraping is not allowed. Mechanical peeling tools and pipe cleaning equipment shall be used. l) All jointing shall take place with alignment clamps. The alignment clamps shall be arranged so that there is no stress on the joint area. Where pipe oval of any joint fitting exceeds the manufacturer’s recommendation the pipe shall be re-rounded by a re-rounding clamp. The re-rounding clamp and alignment clamps shall not be removed until the cool time has elapsed. m) The welder's certification number must be stamped on the bead of each butt welded joint. n) Beads shall not be removed unless specified. C3.4.4 Equipment a) Butt welding machine Details of the butt welding machine, including its age and maintenance history shall be provided with the calibration certificate. Calibration of the machine and heater plate shall be completed to the manufacturer’s specification. The butt welding machine shall not be a manual type. The machine shall be capable of logging (and download to MS Excel) the following:
  • 37. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 37 of 92 • Weld number or identifier • Weld location • Welding machine including model & serial number • Welding operator and certification number • Pipeline label including material type, OD, SDR, the actual mean wall thickness • Date • Time • Ambient temperature • Machine cylinder area and ram ratio • Heater plate area • Software version • Heater plate temperature • Pressure and time parameters achieved: o Drag pressure o Bead build-up pressure and time (P1 & T1) o Heat soak pressure and time (P2 & T2) o Maximum change over time (T3) o Maximum time to achieve weld pressure (T4) o Welding and cooling pressure (P3) o Maximum and minimum bead size after cooling (mm) b) Electrofusion welding control box Details of the electrofusion control box and the data logger shall be provided including their age and maintenance history and evidence that the control box has a current certificate of calibration for Watercare’s acceptance. The electrofusion control box shall be an automatic bar code scanner machine. Calibration of the electrofusion control box shall include calibration and operation checks to the manufacturer’s specification. All electrofusion welds shall be a data-logged recording (and download to MS Excel) of the following: • Weld number or identifier • Weld location • Welding machine • Welding operator and certification number • Pipe and fitting details • Date • Time • The fusion-cool cycle was completed correctly, or • The error code where the fusion-cool cycle did not complete correctly c) Miscellaneous equipment • Petrol chain saws shall not be used to cut PE pipe. Large diameter PE pipe may be cut using an electric chainsaw without the chain oiler operating, or an electric reciprocating saw, or specialised PE pipe cutter. Smaller diameter PE pipe, <300mm OD, shall be cut with a rotary pipe cutter or clean hand saw. • Isopropyl Alcohol (IPA) having a concentration of 95% or greater shall be used for pipe cleaning prior to welding. IPA wipes specifically for PE electrofusion welding or IPA liquid with lint free cotton cloth is accepted. Acetone is not allowed. • Alignment clamps shall be used. The clamp leg shall be 2.5 to 3 times the pipe OD in length with at least 2 clamps on each leg.
  • 38. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 38 of 92 C3.4.4 QA/QC templates This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Work Method Statement Document provided and accepted Required Required Required 2 Pipe inspected No visual damage, eccentricity and dimensions to AS/NZS 4130 N/A Required As specified 3 Welding machine calibration Calibration certification current Required Required Required 4 Training & competency certification of operators NZQA recognised qualification. Current experience in pipe size and type to be welded. Required Required Required 5 Pre-qualification weld test results All welds ductile. NATA/IANZ accredited laboratory test to ISO 13953/4/6, ISO 21751 Required Required N/A 6 Welding data Logging Excel format with required data Required Required Review document 7 Tent/ shelter over welding Site inspections N/A Required As specified 8 Pipe ends sealed during welding Site inspections N/A Required As specified 9 Construction weld test results Ductile. NATA/IANZ accredited laboratory test to ISO 13953/4/6 Required Required Review document 10 Clean working space, no mud or standing water on trench floor Site inspection N/A Required As specified Butt weld specific 11 Butt Weld parameters Calculated by pipe size and type Required Required N/A 12 Heater plate manual readings (4 per day) Daily checks completed – forms supplied Required Required N/A 13 Weld beads inspected (butt welding) Tolerances to POP003 N/A Required As specified Electro-fusion joint specific 14 Pipe surface preparation Using mechanical peeling tool (no hand-scraping) >0.2mm < 0.5mm material removed N/A Required As specified Sign-off
  • 39. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 39 of 92 Daily Heater Plate Temperature QA Check Sheet Contract No. Date: Welder: Time Time Pipe Size Pipe Size Show position of pipe and temperature check locations Show position of pipe and temperature check locations Temperature at Position °C Temperature at Position °C 1. 2 1. 2 3 4 3 4 Time Time Pipe Size Pipe Size Show position of pipe and temperature check locations Show position of pipe and temperature check locations Temperature at Position °C Temperature at Position °C 1. 2 1. 2 3 4 3 4
  • 40. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 40 of 92 C3.5 Repair of polyethylene pipe a) This section shall be read in conjunction with the requirements for the installation of polyethylene pipe (section C3.4) and the material and mechanical standards applying to the specific repair solution. b) The repair of PE pipelines may be achieved using butt welding, electrofusion welding and PE mechanical connectors. Generally butt welding is unsuitable in most repair situations and is more practical for off-site fabrication of repair pieces. c) The type of failure shall be identified before affecting a repair. The repair method must be approved by the Watercare. The typical failure modes and repair solutions are: Table C3.5-1 PE repair solutions Type of Failure/Damage Acceptable Repair 1 Very small scale mechanical damage - surface gouge or abrasion Electrofusion repair saddle 2 Damage at high point where control of water in pipeline not a concern Cut-out damaged section of pipe and replace using PE pipe spool and electrofusion couplers 3 Mechanical damage - such as excavator strike Cut-out short section of pipe and replace using electrofusion flange adapter, or mechanical flange adapter 4 Pinhole leak Cut-out short section of pipe and replace using electrofusion flange adapter, or mechanical flange adapter 5 Broken butt-weld Cut-out short section of pipe and replace using electrofusion flange adapter, or mechanical flange adapter 6 Large scale mechanical damage - such as pipe scoring Cut-out affected section of pipe and join-in new pipe spool using electrofusion flange adapter, or mechanical flange adapter 7 Brittle cracking including slow crack growth (SCG) failure Cut-out affected section of pipe and join-in new pipe spool using electrofusion flange adapter, or mechanical flange adapter d) For any welded type repair the pipe shall not be backfilled or returned into service before the required cooling time has lapsed. e) It is preferred that joints are repaired by butt or electrofusion welding. Non-welded joints shall be flanged or use an accepted proprietary self-restrained product used. f) The repair solution class and pressure rating shall be the same or greater than the existing pipe. C3.6 Installation of welded steel pipelines Steel pipe may be installed by various methods depending on the purpose of the pipe. The requirements in this section apply to the permanent installation of steel pipe for purposes other than unprotected or sacrificial sleeves, in a trench or above ground. C3.6.1 Pipe bends and other assemblies a) This section shall be read together with the mechanical construction standards. b) Any tapers or bends shall be constructed to the dimensions as specified by the drawings for steel pipe assemblies. c) Pipe internal linings or external corrosion protection shall be of the same parent product as the main pipeline or similar accepted alternative according to the operational requirements. d) Linings and external corrosion setback shall allow for site installation and jointing. C3.6.2 Pipe joints a) Socket and spigot joints shall be drawn fully home using safe working practices that do not deform the pipe or damage internal linings.
  • 41. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 41 of 92 b) A full fillet weld structurally joining the pipes shall be made externally and internally (pipelines >700mm), in accordance with the standard drawings and the mechanical construction standard. No person shall enter any pipe for internal work where a body needs to fully enter the pipe on pipes less than 700mm internal diameter. c) Where it is necessary to deflect a joint the maximum deflection for steel pipe socket and spigot joints is listed in the table below: Table C3.6.2 -1 Allowable spigot and socket joint deflection Nominal bore (NB) mm Maximum deflection angle (degrees) 150 7 200 6 250 5.5 310 5 390 5 470 4.5 550 4 630 4 700 3.5 730 4 760 4 810 4 910 3.5 1070 3.5 1300 3 1500 3 1700 3.5 1900 3 d) Pipe assemblies without a formed spigot and socket shall be installed using welding bands in accordance with the standard drawings or as otherwise directed by the specific drawings. e) Flanges and isolation joints or other mechanical couplings shall only be installed in accordance with the design drawings. For details of forming mechanical joints the mechanical construction standard shall apply. f) Access manholes to Watercare standard design shall be installed on pipework of 700mm diameter or larger to facilitate safe access to complete internal pipe welding. The location of access manholes shall be at the discretion of the contractor and stated in the work method statement. The frequency and type of access manhole used shall be submitted to Watercare for acceptance. g) The internal pipe lining shall be repaired for all pipe joints where the steel is exposed. Any rust, loose paint or other deleterious matter shall be removed. Repairs (epoxy and mortar compliant with AS/NZS4020) shall be completed in accordance with the lining product instructions. Where concrete lining is used the repair shall be smooth and continuous with the original lining either side of the joint. h) Concrete lined pipes smaller than 700mm in diameter, or where the pipe joint cannot be reached for internal repair without entry, shall be repaired by other means. Solutions may include that the internal joint be prepared with an accepted rapid setting mortar before the joint is closed or where welding bands are used a temporary inflator expanded against the joint allowing the lining to be repaired by external injection of the grout. Accepted proprietary internal joint repair products or the use of robotics may be other solutions. C3.6.3 Corrosion protection a) Internal coating or lining shall be applied in accordance with the applicable material supply standard for the specified service application. b) Concrete lining repairs shall be made to any cracks, defects or weld joints where the concrete lining separation is greater than 1mm. An accepted product shall be used that is fully tested to comply with AS/NZS 4020. Refer to section C3.6.2 g), h) for internal lining repair at pipe joints.
  • 42. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 42 of 92 c) An accepted tape coating shall be used as external protection for buried pipe and pipe assemblies and be applied in accordance with the product manufacturer specification. Pipe lengths shall be factory wrapped. Pipe assemblies shall be wrapped by the fabricator. Only joints, site installed fittings or repairs shall be wrapped on site. d) The construction and quality assurance for the tape coating systems shall comply with the requirements of AWWA C209 except: • Apply primer to the bare steel surface and overlapping 150mm over the existing wrapping • The tape shall be applied in a smooth wrinkle free coating with a minimum spiral overlap of 67% to achieve three layers e) External epoxy coating for exposed pipe shall be factory applied for pipe lengths. Pipe assemblies shall be prepared and painted by the fabricator. Surface pipe shall be epoxy paint coated to the applicable painting standard. (See section C5) f) Where pipe transitions from buried to painted pipe above surface an ultraviolet resistant protective tape system shall be applied with an overlap of at least 150mm below ground onto the buried protective wrapping, extending to 500mm beyond where the pipe is clear of the buried surface. g) Direct current voltage gradient (DCVG) integrity testing shall follow visual inspection. Any holidays found shall be repaired and retested. Refer to Section 10.12 for testing requirements. C3.6.4 Concrete lined steel pipe - Wastewater specific requirements a) Minor grading deflection shall be achieved within the spigot joint or welding band allowable tolerances. b) Pipe bends are only allowed for pressure systems. Directional change for gravity systems shall be through a wastewater manhole in accordance with the standard drawings. C3.6.5 QA/QC templates This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Socket deflection Within limitations of table C3.6.2-1 (measure/survey) (per joint) Required Required N/A 2 Weld band, socket and spigot joint test Nitrogen/air test pipe ≥700mm test record (per joint) Required Required Review document 3.1 Corrosion protection 3 layer overlap (67% per lap) N/A Required As specified 3.2 Pull test as per AWWA C209 Required Required Review document 3.3 Visual inspection N/A Required As specified 3.4 DCVG survey test results Required Required N/A 4 Components for use with potable water AS/NZS4020 compliant Required Required N/A Sign-off C3.7 Installation of PVC pipelines a) This section shall be read in conjunction with section C3.1. b) Pipe delivered to site shall be checked for any damage and completeness (gaskets in place). The pipe class and dimensions shall be confirmed to be in accordance with the specific drawings and the applicable material standard. c) PVC pipe shall be protected from ultraviolet exposure. d) Particular care shall be taken to prevent seals being exposed to heat, oil, grease or other contaminants. C3.7.1 Pipe Joints a) Pipe joints shall be made to the manufacturer’s requirements. b) Pipe may be cut using a power handsaw or a clean hack saw.
  • 43. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 43 of 92 c) The end of the pipe shall be bevelled at 15ᵒ for 50% of the pipe wall thickness with a purpose bevelling tool or fine wood rasp. The bevel shall be consistent around the pipe circumference and free of any burrs. d) An accepted lubricant shall be applied to the joint in accordance with the manufacturer’s requirements. Lubricants shall be compliant with AS/NZS4020. e) The pipe joints shall be aligned vertically and horizontally driving the joint in. The bar-and-block method shall be used to make the joint. On large pipe diameters mechanical assistance may be required. Reference lines shall be used to prevent excessive force and to ensure the joint is fully home. C3.7.2 QA/QC template This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Pipe joint lubricant Compliant with AS/NZS4020 Required Required Required 2 Socket preparation Pipe bevelled and free of burrs N/A (per joint) Required As specified 3 Socket witness marks Joints drawn fully home N/A (per joint) Required As specified Sign-off C3.8 Installation of Ductile Iron (DI) pipe a) This section shall be read in conjunction with section C3.1. b) Pipe delivered to site shall be inspected for defects including but not limited to lining and external coating defects, gasket condition (spigot jointed pipes) or conforming flange requirements and cracks. c) Pipe protective coatings shall be holiday tested. Repair to any defects identified shall be corrected in accordance with Section C3.6.3. C3.8.1 Pipe Joints a) Pipe joints shall be made to the manufacturer’s requirements. Where other mechanical joints, in particular flange joints are approved by Watercare, please see the mechanical construction standard jointing requirements. b) Spigot and socket joints shall be installed with the socket (bell) facing the direction of installation. The end of the pipe shall be bevelled at 15ᵒ for 50% of the pipe wall thickness. The bevel shall be consistent around the pipe circumference and free of any burrs. c) An accepted lubricant shall be applied to the joint in accordance with the manufacturer’s requirements. The pipe joints shall be aligned vertically and horizontally before driving the joint in. The bar-and-block method shall be used to make the joint. On large pipe diameters mechanical assistance may be required. Reference lines shall be used to prevent excessive force and to ensure the joint is fully home. d) Mechanical joints shall be fitted in accordance with the manufacturer’s requirements and protected against corrosion as per Section C3.6.3. C3.8.4 Pipe deflection with spigot joints a) Where pipe is required to be deflected over a long radius the deflection may be achieved in deflecting the spigot joints. b) The installation of the joint shall be straight as per Section C3.8.1 and the deflection only applied once the joint is fully drawn. c) The deflection shall be applied to the manufacturer’s recommendation. In the absence of manufacturer data the following formula shall be applied as a guideline:
  • 44. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 44 of 92 R = L/( 2 tan Ɵ/2) Where: R = Radius of curve (metre) L = length of pipe (joint to joint in metre) Ɵ = Deflection angle (degrees) Allowable angle deflection angle per joint Nominal pipe size (mm) Deflection angle Ɵ (degrees) 80 5 100 5 150 5 200 4 250 4 300 4 350 3 400 3 450 3 500 3 600 3 700 2 800 2 900 1 1000 1 d) All joints must be checked on site to ensure that joint seals make full contact and are fully functional. C3.7.2 QA/QC template This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Socket preparation Pipe bevelled and free of burrs N/A (per joint) Required As specified 2 Socket witness marks Joints drawn fully home N/A (per joint) Required As specified 3 Corrosion protection Holiday testing for coating defects. Defect repaired N/A Required As specified Sign-off
  • 45. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 45 of 92 C3.9 Concrete and Ceramic pipes (Wastewater only) C3.9.1 General a) This section shall be read in conjunction with section C3.1. b) Pipe joints shall be made to the manufacturer’s requirements. c) This section covers concrete pipe for wastewater application, both gravity and pressure applications. d) Pipe delivered to site shall be inspected for defects. Damaged or broken pipe shall not be accepted. e) Pipe may not be unloaded by rolling to ground or similar that would result in impact on the pipe. f) Pipe shall be kept clean. g) Rubber rings shall not be stored in sunlight and care shall be taken with storage to prevent deformation. C3.9.2 Cutting of pipes a) The cut shall be made using a diamond or abrasive saw. Explosive or impact chisel methods shall not be used for cutting pipes. b) The whole cut shall be in the same plane through the full thickness of the pipe wall, and shall be within a tolerance of 6 mm from the true cut line. c) Pipe reinforcing shall be cut cleanly and flush with the finished concrete surface. C3.9.3 Pipe Laying a) Bedding requirements shall be in accordance with the standard drawings for concrete pipe. Unless otherwise shown on the specific drawings, the bedding shall be Type H2. b) Concrete bedding shall be in accordance with the requirements in section C4: • Concrete need not be weight-batched. • Curing is not required. c) The surround material shall be placed as soon as possible after the pipes have been inspected, any concrete bedding has attained sufficient strength and the testing requirements have been complied with. d) Compaction and backfilling shall be to the general requirements. C3.9.4 Laying on a curve a) Pipe laying on curves shall be as specified or shown on the specific drawings. b) Pipe joint shall be to the manufacturer recommendations. c) Where pipes with rubber ring joints are to be laid on curves and the curves are to be taken up in the joints, each pipe shall be entered and pushed home with the pipe in line with the previous pipe. The deflection required to make the curvature shall be made by moving the free end by the required amount. C3.9.5 Rubber ring joints Rubber ring joints shall be made to the pipe manufacturer’s requirements, and: • Out of alignment joint shall not be forced, but parted and remade. • Joints shall be inspected to ensure the rubber ring is in its location (checked with a feeler gauge) and free of twists. C3.9.6 Mechanical joints Mechanical joints shall be installed in accordance with the mechanical construction standard. All joints shall be wrapped with an accepted corrosion protection system. C3.9.7 Repair Refer to section C4.7 for repair and rehabilitation of concrete pipe for wastewater applications.
  • 46. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 46 of 92 C3.9.8 QA/QC Template This template is in addition to C3.1.8 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Pipe inspection Free from damage. Seals stored appropriately N/A Required Required 2 Pipe cutting 6mm tolerance N/A Required As specified 3 Pipe laying Bedding type as specified (per section). Type H2 normative if not specified N/A Required As specified 4 Laying on curve – under approval and to the required standard method N/A Required As specified 5 Joints Fully drawn, inspected for defects N/A Required As specified 6 Mechanical joints wrapped to manufacturer requirements N/A Required As specified 7 CCTV CCTV inspection – Reviewed for defects Required Required Required 8 Testing & disinfection Testing requirements for pressure or non-pressure pipe as appropriate Required Required Required Sign-off C3.10 Pipe structural lining C3.10.1 General a) A pre- and post-lining close circuit television (CCTV) inspection shall be completed. b) The pre-lining CCTV assessment shall be to confirm the pre-replacement condition and to verify the lining solution. c) Lining solutions with any compounds or lubricating systems used in potable water applications shall be fully tested to comply with AS/NZS 4020. C3.10.2 Access a) Siting of access locations shall be provided for Watercare’s consideration as part of the construction management plan. b) Where access is obtained through chambers, existing lids or similar infrastructure, best care shall be taken to retain these for re-use. c) The pipeline shall be accessed on approval and only after shutdown is confirmed by Watercare. A minimum of five working days’ notice is required prior to any shutdown, but may be extended due to operational constraints. C3.10.3 Pipeline cleaning a) Cleaning prior to CCTV shall only be completed where sediment deposits are likely to obscure defects. Cleaning methods may include: • Water scour • Air scour • Swabbing or pigging • Water jet b) The construction management plan shall include any cleaning method limitations considering the pipe material, class and expected condition to conserve the pipe’s integrity. C3.10.4 CCTV requirements a) The CCTV shall be produced in accordance with the Watercare Data and Asset Information standards for inspection and collection of data.
  • 47. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 47 of 92 b) Survey logs shall be provided identifying all visible defects, including measurements of the existing lining thickness on the vertical and horizontal axis at each end of each pipe section. C3.10.5 Pipe repairs a) Prior to the relining of each section, where a section of pipe has been removed at a fitting, a single pipe section shall be provided to make up the whole distance between the fitting and the end of the pipe. b) The installation of replacement pipe sections is not required where it is demonstrated that the liner system shall fully withstand all internal and external loads. c) In the case of steel or ductile iron pipe the acceptable protective wrapping shall be applied to the manufacturers’ instruction or as otherwise amended by the general construction standards. C3.10.6 Polymer lining methods a) The polymer lining method shall be appropriate for the pipeline faults. The lining material shall be fully structural. Methods for pressure water applications are: • Swage lining • Cure in place pipe (CIPP) • PE slip lining • PE fold and form b) Unless specified, the contractor shall provide the following information based on the selected lining type: • Hydraulic, soil and dynamic loads • Lateral consideration resulting from adhesion to the host pipe • Material type selection in accordance with the above loading criteria • In the case of slip lining the annulus grouting procedure c) Connections and joints: • Joints shall be welded between connection points. • The welding practices shall be in accordance with the general construction standard for the applicable material type. • Connections such as tees, bends or valves shall be with a purpose adaptor for the lining type. • Connections made with ductile iron or steel are permissible on the condition that the joint between the host, lining and new fitting provides the desired structural integrity. C3.10.7 Cement and mortar in-situ lining methods a) For wastewater applications refer to Section C4.7. b) The cement mortar lining shall be machine applied to 10mm thickness with an allowable variance of ±1.5mm. c) Any fittings attached to the pipe shall be prevented from blocking, and where able, the lining shall be hand finished. d) Any hand reinstatements of fitting connections or small patch repairs shall be within 24 hours of the machine application. Where the machine accessed the pipe, the machine application shall be fully completed with the machine, cut back 75mm and hand rendered. e) The mortar lining shall be allowed a minimum of 72 hours curing time. f) Steel pipe that has been cut open shall be prepared with an acceptable high heat resistant mortar that will seal the mortar behind the weld. This mortar shall be allowed to cure according to the manufacturer’s recommendation before completing the weld. Surface preparation: The cleaning effort shall be such that the pipeline is a bare surface without any loose debris or rust. Concrete lined pipe shall be cleaned without damage to the existing concrete or concrete lining. C3.10.8 Record keeping a) The record form shall be completed per component rehabilitated or in the case of pipelines between access points, batches or shifts. b) Records for polymer lining systems shall follow the requirements for the material type within this standard. For mortar lining the following template shall be used:
  • 48. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 48 of 92 Structure information Contractor Installation site identifier Asset ID Address Access location Grout mix Date Time Manufacturer batch number Mix composition Mix Volume C3.10.9 QA/QC Template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 CCTV - start Records evaluated against design stage records Required Required Required 2 Pipe cleaning AS/NZS 1516 preparation for lining. N/A Required As specified 3 Product compliance Watercare material standards Required Required Required 4 Mortar application records Min. 10mm, ±1.5mm. Required Required Review document 5 Testing Samples to AS 1012 part 24, tensile bond strength (mortar lining) Required Required Review document 6 Pressure testing and weld samples as per the general civil standard Required Required As specified 7 CCTV – final U3 finish. No visible slumping or cracking Required Required Required Sign-off C3.11 Pipelines brought into service a) All construction test certifications and required operational documentation shall be provided before applying to bring the pipe into service. b) The pipe shall then be leak tested and made ready for final connection. For more information refer to the Watercare Code of Practice for commissioning. Note – Where disinfection of pipes are required before making the connection, the disinfection and testing shall be done as part of bringing the pipe into service due to chlorine retention times. See Watercare’s code of practice for water reticulation disinfection. c) A method statement for final connection works shall be provided for acceptance a minimum of four weeks before the programmed cut-in. d) The method statement shall include but not be limited to: • Position of “stop-ends” to minimise the length of untested section when making the final connection • Test water source and disposal • Plant, equipment and resources to be used • Programme • Lines of communication
  • 49. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 49 of 92 C4. Concrete C4.1 Construction of reinforced concrete structures a) Where concrete is used in conduits, water retaining structures and manholes, the provisions of NZS 3106 shall apply. NZS 3106 will take precedence over NZS 3109, where there is conflict. No calcium chloride shall be used in reinforced concrete. b) Concrete mix shall achieve 28 day strength of 30MPa unless otherwise specified. c) The ratio of 7 to 28 day strength shall be as specified but not less than 1.3 (or 60% of 28 day strength). d) Construction shall not progress if the 7 day test indicates concern of achieving full 28 day strength. e) Where concrete is used in conduits, water retaining structures, manholes, sewage chambers and wet wells or where concrete is in contact with the ground, the water-cement ratio shall not exceed 0.5. f) Air entrained concrete shall not be used in lifts greater than 2.5m. Concrete shall be placed in its final position within 1½ hours of cement introduction to the aggregates. The time lapse for concrete handling from the mixer or agitator truck shall not exceed 30 minutes. g) Concrete pumping shall follow the contractor’s methodology, designed task specifically and as accepted by Watercare, observing the following: • Aluminium pipes shall not be used • A lubricating mortar run to waste shall be used at the pump start • Slump test at the supply hopper and placement end pipeline • Concrete compression test samples shall be taken at the placement end h) In addition to Clause 7.7.1 of NZS 3109, should rain threaten an exposed concrete pour, suitable covers shall be put in place before the pour commences. i) Curing compounds shall only be used where specified, less than 6 hours after screeding to the manufacturer’s requirements and shall restrict the loss of water to less than 0.55 kg/m2 in 72hours. C4.1.1 Reinforcement a) Reinforcing shall be inspected and certified in accordance with the supply standard before installation and before concrete is placed. b) Reinforcement shall be placed straight between specified bends. c) All deformed bar reinforcement, noted on the drawings as either H or HD followed by the bar size, shall be Micro Alloyed manufacture Grade 500 ductility Class E to comply with AS/NZS 4671 carrying the SEISMIC 500E MA identifier. d) Plain round reinforcing, noted on the drawings as R followed by the bar size, bar shall be Grade 300 complying with AS/NZS 3679.1 e) Pre-stressed reinforcing shall comply with AS/NZS 4672 to the specific design. f) Approval to weld reinforcement is required in every case and drawings shall be included with each application for approval showing the position and type of each weld. Welds shall be in compliance with AS/NZS 1554 part 3. Welds shall be more than 10x bar diameters from bends. g) In addition to the requirements of NZS 3101 and NZS 3190, the manufactures instructions with respect to the bending and re-bending of steel shall be strictly followed. Details can be found at www.reinforcing.co.nz. h) The concrete cover to steel reinforcement shall be the greater of: • The values given in NZS 3101:Part 1, or • the values given in the tables below (design life specific, normally 100 years), or • the cover shown on the drawings.
  • 50. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 50 of 92 Table C4.1.1-1 Minimum required cover for a specified intended life of 50 years Exposure classification Cement binder type Specified compressive strength fc’ (MPa) 25 30 35 40 45 50 60-100 Minimum Required Cover (mm) Al GP, GB or HE 25 20 20 20 20 20 20 A2 GP, GB or E 35 30 30 25 25 25 20 BI GP,GB or HE 40 35 35 30 30 30 25 B2 GP,GB or HE - 45 40 35 30 30 25 C(1) 30% FA - - - 60 60 60 55 C(1) 65% GBS - - - - 50 50 50 C(1) 8% MS - - - - 60 50 50 Notes: 1. For zone C the total binder content shall be equal to or greater than 350kg/m3 and water to binder ratio shall not exceed 0.45. The minimum cover for the C zone shall be 50mm. Table C4.1.1-2 Minimum required cover for a specified intended life of 100 years Exposure classification Cement binder type Specified compressive strength fc’ (MPa) 25 30 35 40 45 50 60-100 Minimum Required Cover (mm) Al GP, GB or HE 35 30 30 30 30 30 25 A2 GP, GB or E 50 40 40 35 35 35 30 BI GP,GB or HE 55 50 45 40 40 35 30 B2 GP,GB or HE - 65 55 50 45 40 35 C(1) 30% FA - - - - 70 60 60 C(1) 65% GBS - - - - 60 50 50 C(1) 8% MS - - - - - 50 50 Notes: 1. For zone C the total binder content shall be equal to or greater than 350kg/m3 and water to binder ratio shall not exceed 0.45. The minimum cover for the C zone shall be 50mm. Abbreviations used in the above tables are as follows. (Refer to NZS 3101: Part 1 for full definition) FA fly ash GB general purpose blended cement HE high early strength cement MS amorphous silica GBS ground granulated iron blast furnace slag i) The minimum cover for a surface in contact with the ground shall be 75mm, or 50mm if using a damp proof membrane between the ground and concrete. j) Unless otherwise specified, the cover required for exposure classification B2 with an intended life of 100 years shall be used. C4.1.2 Construction joints a) Construction joints shall be in continuous unbroken lines. Unless otherwise specified construction joints shall be as shown on the specific drawings. b) In water retaining structures, immediately before placing the new concrete on a horizontal joint the roughened surface shall be primed with a neat cement grout layer of 5mm thickness and a water cement ratio less than 0.32. c) Any alternative joint surface preparation shall be subject to approval. C4.1.3 Contraction joints a) Contraction joints shall be formed where specified.
  • 51. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 51 of 92 b) In water retaining structures the joints shall incorporate an appropriate water stop unless otherwise specified. c) The surfaces of contraction joints shall be left smooth. Where details of contraction joints are not shown on the specific drawings a tapered rebate shall be formed in the joint. The taper will have an average width of one third of the thickness of the concrete and a depth of not more than half the width. C4.1.4 Slump tolerance For water retaining structures, slump tolerances shall be half those given in Table 9.1 of NZS 3109. C4.1.5 Vibration Internal vibrators shall be on approval. If scum, devoid of coarse aggregate appears on top of or ahead of concrete after specified compaction (Clause 7.5.5 of NZS 3109), the laitance layer shall be removed to waste and replaced with concrete and before any consecutive layers are placed. C4.1.6 Surface finish Formwork, concrete proportions and workmanship shall be such that no patching of concrete surfaces will be required. The minimum standard of surface finish shall be as indicated in the table below. A uniform finish standard shall be provided to any designated location. Table C4.1.6-1 Minimum standard of surface finish Location Surface finish Concealed foundation surfaces F1 Top surface of foundation pads U2 Visible foundation surfaces F5 Site concrete U1 Interior walls F3 Exterior walls F5 Floor and roof slabs U2 Formed concrete to take plaster F2 C4.1.7 Penetrations through structures a) All embedded items shall be accurately set and supported in place until the concrete has set. In addition to Clause 5.5 of NZS 3109: • Place such pipes or items in the forms before placing the concrete, or • Provide approved block-outs in the forms • Position penetrations on construction joints to minimise shrinkage cracking where feasible • Construction joints around block-outs shall have approved keys formed and/or be roughened to an amplitude of 5mm • Block-outs shall be shaped to allow removal of all air displaced by the subsequent grouting of the penetration b) When grouting in pipes and other items, concrete grout (or approved alternative) of at least equal strength to the surround concrete shall be used. An acceptable expansive admixture, applied in accordance with the manufacturer’s instructions shall be used in the grout to ensure a watertight joint. c) Penetrations for pressure rated pipe (other than thin walled sleeves) shall be sealed against water ingress with an overlapping strip of an acceptable hydrophilic sealant encased at least 70mm in the concrete casting. d) Penetrations to the structure shall be grouted in place by placing the grout under a head of at least 100 mm. The concrete shall completely fill the spaces to achieve the same water tightness as the rest of the structure. e) Pipes less than 75 mm diameter in cored holes shall be fixed in place by dry pack mortar or cement grout with a suitable bonding agent. C4.1.8 Records In addition to Clause 303.1 of NZS 3104, the mix design shall be identified and any admixtures shall be included on the delivery docket.
  • 52. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 52 of 92 C4.1.9 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Concrete construction plan Including delivery scheduling plan to meet timeframes Required Required N/A 2 Confirm required concrete strength As specified or minimum required from this standard Required Required Required 3 Reinforcing inspection According to specific drawings Required Required Required 4 Deformed bar SEISMIC 500E. Test certification of steel required Required Required Required 5 Plain bar grade 300. Test certification of steel required Required Required Required 6 Welding 10x dia. from bends Required Required Required 4 Formwork Cover requirement met, Tables C4.1.1 -1/2 Required Required Required 5 Concrete plant certification Certification graded ready mixed concrete plant to NZS3104 (High grade or special grade) Required Required Review document 6 Vibration Witnessed to comply with requirements of NZS3109, any laitance replaced N/A Required As specified 7 Test reports Supply source Required Required N/A 8 Mix identification and compressive strength Required Required Required 9 Location of structure Required Required N/A 10 Batch number Required Required N/A 11 Time and date Required Required N/A 12 Time prepared Required Required N/A 13 Slump 0.5x values of table 9.1, NZS 3109 Required Required Required 14 7 day test Required Required Required 15 28 day test Required Required Required 8 Construction and contraction joints Inspected as per drawings N/A Required As specified 9 Surface finish Table C4.1.6-1 N/A Required As specified 10 Testing tanks and reservoirs Complete test to Section 10.5.4 Required Required Required Sign-off C4.2 Construction of enclosed chambers, manholes and small structures C4.2.1 General a) Concrete mix shall be minimum 25 MPa at 28 days unless shown to be a higher strength on the specific drawings. b) For manholes the concrete haunching and encasement to pipe penetrations shall be from 25MPa grade concrete and shall be formed such that the inside face follows the original inside line of the manhole. c) Wastewater manhole benching shall be cast and troweled to shape, sloping towards the channel at minimum 1:12. The troweled surface shall be smoothed to U2 finish. Plastering over the concrete finish is not accepted.
  • 53. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 53 of 92 C4.2.1 Foundation The structure shall be founded on a firm and stable base, with site concrete as required, to provide a clean working surface for construction of the manhole. C4.2.2 Roof slab, lids and access a) All lids shall support HN-HO-72 loading. Access holes and other entry points shall be cast into the slab, not cut. b) The lids shall be fixed to the slab as shown in the standard drawings. c) Person accessible entries shall have a minimum clear access of 600mm diameter. Entries or other openings where a person can fall into a pit or chamber with the access lid removed, shall be fitted with an accepted safety grille. d) Step rungs or ladders shall be as shown on the drawings and manufactured from an accepted material to the Watercare material supply standard. Refer to Watercare’s mechanical construction standard for construction and installation requirements. C4.2.3 Infiltration performance The sealing between joints shall be with an acceptable material providing 100 year performance and installed to the manufacturer’s requirements. The sealing material shall meet the minimum infiltration test performance criteria applicable to the installation circumstances. C4.2.4 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Set-out Line and level in accordance with specific drawings N/A Required N/A 2 Foundation Inspected, sound/firm N/A Required As specified 3 Concrete Records: Min 25 MPa or higher as specified Required Required Review document 4 Penetrations All cast in place N/A Required Required 5 Vertical Survey Required Required N/A 6 Infiltration Applicable test per Section 10.5.2 Required Required Required 7 Roof slab/Lid HN-HO-72 certified (where constructed in road-way) Required Required Review document 8 Access lid Appropriate load class fitted Required Required Required Sign-off C4.4 Shotcreting C4.4.1 General Concrete shall comply with the requirements of Section C4.1 of this standard. Shotcrete shall be applied using the wet mix process. C4.4.2 Preparation and trial a) Shotcrete specimens shall be sampled and tested for compliance prior to construction. b) Remove all unsound material before applying shotcrete. Chip or scarify any area to be repaired to remove offsets without suitable reinforcement. Taper the edges to remove square shoulders at the perimeter of a cavity. Remove all loose material from areas receiving shotcrete. c) Wet the surface until it is damp, but without visible free water. Do not place shotcrete on frozen surfaces. d) Sandblast existing surfaces that do not require chipping to remove paint, oil, grease, and other contaminants and provide a roughened surface for bonding.
  • 54. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 54 of 92 C4.4.3 Placement of shotcrete a) Shotcrete shall only be undertaken by experienced, specialised persons able to demonstrate work experience of a similar type to the work being undertaken. b) Control thickness, method of support, air pressure, and/or water content of shotcrete to preclude sagging or sloughing off. Discontinue shotcreting and provide suitable means to screen the nozzle stream if wind or air currents cause separation of the nozzle stream during placement. c) Broom or scarify the surface of freshly placed shotcrete to which, after hardening, additional layers of shotcrete are to be bonded. Dampen surface just prior to application of succeeding layers. d) Commence by filling all corners and any area where rebound cannot escape or be blown free. Complete the corners between the web and the flanges of structural steel before application to the flat areas. e) Provide a supply of clean, dry air adequate for maintaining sufficient nozzle velocity for all parts of the work, and if required, for simultaneous operation of a suitable blowpipe for clearing away rebound. f) Hold the nozzle at such distance and angle to place shotcrete behind reinforcement before any material is allowed to accumulate on the face. Do not place shotcrete through more than one layer of reinforcing steel rods or mesh in one application unless the steel is properly encased, as demonstrated by pre- construction tests. g) Test to determine if any voids or sand pockets have developed around or behind reinforcement by probing with a pointed tool after the shotcrete has achieved its initial set. h) Use adequate ground wires or other accepted means to establish the thickness, surface planes, and finish lines of the shotcrete. Maintain specified tolerances by keeping ground wires secure and taut. C4.4.4 Finishing a) Provide natural gun finish unless otherwise specified. Avoid trowelling thin sections of shotcrete unless both trowelling and the start of moisture curing take place within a short time after placement. b) Do not remove high spots until the shotcrete is stiff enough to withstand pull of the cutting device. C4.4 5 Joints a) Construct joints as indicated in the specific drawings. Unless otherwise shown, construction joints are to be tapered to a shallow edge from about 25 mm thick. b) If the joint will be subjected to compressive stress, use non-tapered joints and take special care to avoid or remove tapped rebound at the joint. c) Make construction joints perpendicular to the main reinforcement. C4.4.6 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Experienced operator Demonstrated to be suitable for task Required Required N/A 2 Trial 5 samples tested per test panel at 7 days and 28 days. NATA/IANZ laboratory results complying with NZS 3109 Required Required Review document 3 Site preparation Inspected to be clean , cleared of debris, loose soil, sandblasted etc. N/A Required Required 4 Contact surfaces dampened N/A Required Required 5 Placement Ground wires in place/similar to gauge thickness N/A Required As specified 6 Probe for voids N/A Required As specified 7 Joints Per drawings N/A Required Required 8 Testing Test results of cores comply (NATA/IANZ lab tested, NZS3109) Required Required Review document 9 Ultrasonic/impact hammer test of finished area - no voids and thickness meeting as specified. Required Required As specified Sign-off
  • 55. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 55 of 92 C4.5 Formwork a) All formwork design shall be the responsibility of the contractor. Formwork of a structural nature shall be certified by a Chartered Professional Engineer registered with CPEC. b) Formwork shall provide adequate access to perform compaction and be accurately shaped to position, level, finish and dimensions. Joints shall be designed and constructed to withstand the compaction, vibration and loadings imposed during construction and curing. c) The formwork materials shall not absorb moisture and not allowed to bond with the concrete. A non- stain material coating shall be used for surfaces exposed to view. The form-coating material shall not interfere with subsequent bonding to the casting when this is required. d) Formwork bolts shall be allowed for extraction without causing damage to the surrounding concrete. Tie bolt holes shall be treated as type B construction joints for 40mm down the hole and rammed with dry pack mortar or an approved equivalent within two days of formwork removal. The minimum cover to embedded tie bolts shall be 50 mm from the finished concrete surface. C4.6 Concrete defect repairs a) This section applies to new concrete constructed as part of the works that has been inspected and found to be defective. b) Repairs shall only be made that are certifiable and meet the performance requirement and minimum asset life. Other defects shall be completely removed and replaced. c) All non-conforming areas shall be identified in a repair methodology that considers repair material, performance, safety and testing (strength test by NATA/IANZ laboratory) for acceptance by Watercare. d) The area for repair shall be prepared using percussive power tools that will remove all loose, cracked or softened material to leave a clean surface of uncompromised aggregate and concrete. The area shall be free from oils or other contaminating deposits. C4.6.1 Patch repairs a) Defects shall be cut out in straight lines at least 10mm deep. The areas shall be soaked before applying repair material to prevent rapid moisture loss to the adjacent concrete. b) The patch repair material shall be a suitable structural grade modified cementitious mortar, compatible with the existing surface and be crack preventative. In deeper sections the repair material shall be built up in layers to prevent slumping, or as otherwise directed by the manufacturer’s direction. c) The repair shall match the surrounding profile, colour and texture. C4.6.2 Crack repairs Cracks shall be repaired by an accepted structural epoxy injection in a continuous operation. The epoxy shall completely fill the crack to restore the strength of the section. C4.6.3 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Concrete defects Finished concrete inspected for defects by structural engineer N/A Required As specified 2 Methodology Conformed to performance requirements Required Required Required 3 Surface repair Surface inspected - clean and free of loose debris or contaminants N/A Required As specified 4 Product Accepted for compliance with performance requirements of concrete Required Required Required 5 Repair test Accepted methodology. Strength test by NATA/IANZ laboratory Required Required Review document 6 Certification Producer statements Required Required Required Sign-off
  • 56. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 56 of 92 C4.7 Rehabilitation of wastewater pipe and structures with cement mortar C4.7.1 General The cement mortar lining shall be accepted corrosion resistant calcium aluminate cement. Any fittings or connection attached to the structure or pipe shall be prevented from blocking, and where able will be hand finished. C4.7.2 Surface preparation a) Concrete surfaces shall be cleaned without causing damage to the existing concrete or concrete lining. The preparation shall remove all: • Grease, fat, oils, slime deposits, laitance. • Corrosion products, loose or corroded mortar. • Previously applied coatings. • Any substance that could affect the bonding strength. b) Any bacteria formation after cleaning shall be removed and treated before the mortar application commences. C4.7.3 Mortar application a) Mortar thickness shall be a minimum of 25mm with maximum ±1.5mm variance, and allowed to cure according to the manufacturer’s recommendation. b) The mortar repair shall be allowed a minimum of 72 hours curing time or sooner as allowed by the accepted product. c) Application shall be in layers as recommended by the product supplier to prevent slumping. d) Pipe lining shall be machine applied. Any hand reinstatements shall be limited to small patch repairs and be made be within 24 hours of the machine application. e) Where the machine accessed the pipe, the machine application shall be fully completed with the machine, cut back 75mm and hand rendered. f) Steel pipe that has been cut open shall be prepared with an acceptable high heat resistant mortar that will seal the mortar behind the weld. g) The mortar surface finish shall be equivalent to U3. C4.7.4 Record keeping The record form shall be completed per component that is being rehabilitated or in the case of pipelines between access points, batches or shifts. Structure information Contractor Installation site identifier Asset ID Address Access location Grout mix Date Time Manufacturer batch number Mix composition Mix Volume C4.7.5 QA/QC Template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 CCTV - start Records evaluated against design stage records Required Required Required 2 Pipe cleaning HB84-2006 guidelines N/A Required As specified
  • 57. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 57 of 92 Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 3 Product compliance Accepted material Required Required Required 4 Mortar application records Min. 25mm, ±1.5mm. Required Required Required 5 Testing Samples to AS 1012 part 24, tensile bond strength Required Required Review document 6 CCTV – final U3 finish. No visible slumping or cracking Required Required Required Sign-off C5. Painting C5.1 General a) This standard applies to the in-situ application of as per the materials standard for painting of general civil and mechanical infrastructure. b) The appropriate painting system shall be applied for the structure function and location. All preparation including blasting, priming and system application shall be in accordance with the product supplier’s direction. c) Power tool cleaning shall not be used as an alternative to blast cleaning except for those surfaces, which because of their location, cannot be open blasted. d) Coatings shall only be applied to clean and dry surfaces and only in dry weather, except where coating is carried out indoors. Any coating damaged by heat, rain, moisture, or condensation shall be removed and a fresh coating applied. e) Painting shall not continue if any of the following conditions apply, unless otherwise restricted by the manufacturer: • The surface temperature is below 8o C or exceeds 30o C • The surface temperature drops to below 3o C above the ambient dew point • The relative humidity exceeds 85% • Inclement weather such as rain, snow, fog, frost, mist or dust • Excessive high winds f) The above moisture restrictions do not apply to paint applications in damp conditions. Note – Watercare has currently standardised on Altex coatings for its pipework, equipment and in aggressive environments such as wetwells and Belzona for abrasive pump headers. The full manufacturer specifications for the product range and selection for Watercare’s infrastructure is available in the materials standard. C5.2 Painting of pipes, equipment and structures The general colour coding and coating specifications for Watercare pipes and equipment is listed in the following tables. For application details refer to the coating systems in the material supply standard. Table C5.2‐1 Water reticulation services colours Location PBS 5252 Colour No. Colour (Resene) Pipe bridges 12 B 29 Karaka Green Pipework and valves in chambers 16 A07 Boulder Pump station and reservoir pipework 18 E 53 Bahama Blue Pumps 00 A 09 Haze Grey Inlet valves at reservoirs and pump stations 14 E 56 Fun Green Outlet valves at reservoirs and pump stations 04 E 53 Guardsman Red Check valves at reservoirs and pump stations 06 D 45 Peru Tan
  • 58. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 58 of 92 Location PBS 5252 Colour No. Colour (Resene) Valves with actuators and control valves at reservoirs and pump stations 06 D 45 Peru Tan Scour valves at reservoirs and pump stations 08 A 14 Bokara Grey (this is black) Safety handrails 08 E 53 Yellow Monorail beams at reservoirs and pump stations 12 D 43 Trendy Green Pump room, motor room, control room floor 00 A 09 Haze Grey Table C5.2-2 Wastewater reticulation services colours Location PBS 5252 Colour No. Colour (Resene) Pipe bridges 12 B 29 Karaka Green Pipework and valves in chambers 00 A 09 Haze Grey Pump station pipework and valves 00 A 09 Haze Grey Pumps in drywell 00 A 09 Haze Grey Electric motors As Supplied Ventilation fans and ducting Match walls Safety handrails 08 E 53 Yellow Gantry cranes and monorail beams 08 E 53 Yellow Pump room, motor room, control room floor 00 A 09 Haze Grey C5.2.1 External pipe painting a) When pipes are to be painted externally, the prime coat shall be carried around the ends of the pipe and into the socket, to the edge of the concrete lining or to the setback distance Ec (for EC value see spiral weld steel pipe supply standard). b) Where pipes are to be wrapped, the prime coat shall be applied from the wrapping, around the ends of the pipe and into the socket, to the edge of the concrete lining or to the setback distance Ec. C5.2.2 Internal pipe painting a) Pipe assemblies that are not concrete lined shall be painted in accordance with the manufacturer’s requirements. The paint lining shall extend to the setback dimension Ec (for Ec value see spiral weld steel pipe supply standard) from the end of the pipe socket, and the remainder of the socket shall have a primer coat only. b) For concrete lined pipe the paint shall overlap the mortar lining on spool sections by 50mm. C) Painting shall be completed following all welding and before bolting up of valve assemblies. The mating surfaces of flanges shall remain unpainted. Repair mortar used at flanges to fair off a concrete lining against a flange shall not be applied over painted surfaces. C5.2.3 Painting of buildings a) While materials may be obtained from different makers, for any individual paint system, only one maker's products shall be used. This restriction shall not apply to alkyd enamel top coats used for architectural or decorative purposes only. b) Unless otherwise specified, the paint manufacturer’s instructions for the application of any paint system shall take precedence over any general requirement in this section. c) Zinc rich paint shall consist of zinc dust pigment carried in a suitable medium such that on drying, the film shall contain more than 95% of zinc powder. The zinc powder shall contain more than 97.5% of pure zinc.
  • 59. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 59 of 92 d) The painting applications building and its associated components shall be as per the following tables below. Table C5.2.3-1 Paint system, preparation and application Note - See tables C5.2.3-2/3 for codes used in this table for preparation and paint systems. The colour codes correspond to BS5252. Item Preparation Paint system Colour BS 5252 a) Aluminium hatch covers Unpainted b) Cast iron pipework and valves inside control building Refer to the material supply standard 12D43 c) Cast iron pipework in wet well Refer to the material supply standard Light grey d) Copper pipework T9 S8 To match background e) Downpipes, lifting hatch support rails T6 S9 10B21 (to match roof) f) Floor (Concrete) of Switchboard Room TG-2010-108820 (see note) Light grey g) Formica toilet partition, PVC waste pipes Unpainted h) Galvanised steel handrails and ladders T6/T7 S9 12D43 i) Galvanised Steel, fittings and brackets inside valve chamber T6/T7 S9 12D43 j) Gutters - Coloursteel Lichen k) Interior wooden doors and frames T4 S17 Clear l) Roof - upper surface - Coloursteel Lichen m) Roof underside - fibrous plaster T5 S7 White n) Stainless steelwork in wet well or storage tank Unpainted o) Structural Steel, Monorails etc. TG-2010-108802 (see note) 22B19 p) Walls of building & valve chambers, concrete, interior to be unpainted – if nominated as being painted in the particular clauses, use - T1 S1 10B15 q) Walls of building, concrete masonry, Exterior, T1 S2 10A03 r) Walls of building, concrete, exterior to be unpainted, - if nominates as being painted in the particular clauses, use - T1 S2 10A03 s) Walls of building, plasterboard, interior T15 S18 10B15 t) Walls, concrete masonry, retaining or free standing walls, exterior locations Unpainted u) Walls, concrete, interior and ceiling of wet well and access platform T1 S14 White v) Woodwork - roof beams - - Unpainted
  • 60. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 60 of 92 Table C5.2.3-2 Preparation codes for table C5.2.3-1 Treatment Surface and preparation T.1 Concrete and concrete masonry Remove all fins, mortar splashes, efflorescence, and foreign coatings, brush down to remove dust and loose material. Fill all cavities and depressions with an approved filler. Where form oil has been used, scrub down with detergent and water and finish rinse with clear water to remove all detergent. Prime with two coats of masonry sealer/filler; waterproofing compound. T.2 As T1, but dampen before primer coat. T.3 Woodwork Remove all dirt, grease, oil, and crayon marks by sanding as necessary. Plug all knot holes and seal all resinous areas and knots with one coat primer. After priming and fixing, stop nail holes, surface indentations and all imperfections, rub down and brush off. T.4 Remove all dirt grease, oil, crayon marks by sanding as necessary. Plug all knot holes with plastic wood filler. T.5 Fibrous plaster Prepare in accordance with AS/NZS2311 T.6 New zinc, galvanised and zinc spray surfaces Wash with white spirit or purpose-made solvents. T.7 Weathered zinc, galvanised and zinc spray surfaces Remove all salt deposits, dust dirt etc. and scrub with stiff bristle brush, and wash with clean water. T.8 Aluminium mill finish, lead, copper Wash with white spirit and either roughen with abrasive paper or treat with etch primer. T.9 Roughen with abrasive paper and wash with white spirit or mineral turpentine. T.10 Structural steel, iron and welds Remove rust, mill scale and slag to dull brown or grey finish. Normal procedures in combination or separately as necessary - wire brushing, scraping, hammering, flame cleaning, grinding, sanding, etching and/or use of suitable solvent cleaners. Thoroughly rinse after pickling procedure. T.11 Blast clean to Swedish Standard SIS 05 5900 class Sa 2½. Prior to blasting welds shall be ground to remove sharp edges, weld-splatter and other sharp edges. T.12 Flame clean and/or grind or use chemical stripper to remove all primer and mill oil. T.13 Painted steel and cast iron (factory applied) Remove coal tar coating with solvent and clean down.
  • 61. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 61 of 92 Treatment Surface and preparation T.14 Any damaged areas to be wire brushed or sanded to give a clean surface. Wash with white spirit or mineral turpentine. T15 Gypsum Plasterboard Prepare in accordance with AS/NZS2311 T.16 Steel with zinc rich epoxy primer (factory applied) Any damaged areas to be wire brushed or sanded to give a clean surface and recoated with zinc rich epoxy primer. T.17 Existing painted surfaces Clean all areas of grease, oil, dirt and dust. Sand to a matt finish. Table C5.2.3-3 Paint system codes for table C5.2.3-1 System No Paint system S.1 Masonry sealer/filler, two coats 100% acrylic high gloss. S.2 Masonry sealer/filler, epoxy top coat to a dry film thickness of 100 microns. S.3 Masonry sealer/filler, alkyd undercoat, alkyd high gloss enamel. S.4 Exterior sealer, alkyd undercoat, alkyd high gloss enamel. S.5 Alkyd undercoat, alkyd high gloss enamel. S.6 Alkyd primer, alkyd undercoat, alkyd high gloss enamel. S.7 Sealer/filler, alkyd undercoat, alkyd high gloss enamel. S.8 Zinc rich paint, zinc chromate primer, alkyd high gloss enamel. S.9 Zinc rich touch-up, zinc chromate primer or etch primer, alkyd high gloss enamel. S.10 Touch-up shop primer, metal undercoat, alkyd high gloss enamel. S.11 Zinc rich epoxy primer (factory applied), touch-up zinc rich epoxy primer, two coats high build epoxy. S.12 Zinc rich epoxy primer (factory applied), touch-up zinc rich epoxy primer, vinyl etch primer or epoxy primer, alkyd high gloss enamel. S.13 Touch-up shop primer, metal undercoat, high build epoxy. S.14 Epoxy primer, two coats of epoxy high gloss. S.17 Two coats clear varnish. S.18 Two coats 100% acrylic semi-gloss. Paint and surface finish for the motor control panel covered in the specification for Manufacture of Switchboard.
  • 62. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 62 of 92 C5.3 Field touch-up painting a) Touch-up painting will be required at field welds, bolt assemblies, primed-only surfaces, and to areas damaged during transportation, handling, storage, or construction. b) Before touch-up painting: • All damaged paint film shall be removed • All grease, oil, dirt or other foreign matter shall be removed • All edges of sound paint shall be feathered by sanding or grinding • Existing gloss paint surfaces shall be sanded or abraded for bond (an exception can apply to some urethane topcoats, to be confirmed with the paint manufacturer) c) Bare spots that have exposed the prime coat but not the base material shall have one or two finish coats applied to regain the specified film thickness. d) If the base material or substrate has been exposed the area shall be cleaned down to the base metal in accordance with either SSPC SP-3 or SSPC SP-11, and the area touched up as specified by the manufacturer’s specification. e) Where corrosion has occurred in the base metal due to the damage to the paint system, the area shall be re-cleaned to the original surface preparation requirement and the full specified coating system applied. C5.4 Protection of work and adjacent equipment a) Before commencing any painting work, all exposed hardware and fittings that might be damaged by paint shall be removed and stored ready for re-fixing in the original condition upon completion of the work. b) Any items not to be blasted or painted (e.g. machined faces, instruments, threaded surfaces, tags, and name plates) are to be adequately masked to protect from blasting damage or overspray. Any overspray or over blast is to be promptly made good. c) Clamps or sorting hooks shall be used for handling steel after the prime coat has been applied. Wire rope or chain chokers shall not be used. d) After the finish coat has been applied, only nylon ropes or rubber covered slings may be used for handling steel during loading, unloading or erection. e) The Contractor shall rectify any damaged coating. C5.5 Valve box cover paint colours Service component Location Colour Hydrant Water retail networks Yellow Valves (Peat valves, shut-off valves, air valves Water retail networks White Water transmission Blue Water meter boxes Water retail networks Black Special controlled zone isolation valve (normally shut position) Water retail networks Red Pressure boundary kits and valves on rising mains Wastewater retail networks Red Grey water (all component) Grey water Purple C5.6 Painting equipment a) Equipment shall comply with the recommendations of the coatings manufacturer. Unless otherwise specified: • Application for coatings is by airless spray or air-assisted airless spray • Use heavy duty conventional spray equipment or high-volume low-pressure (HVLP) equipment at the correct air and fluid pressures to give correct application • Brush application is restricted to those areas which cannot be spray-coated due to difficult access or complex shape • Non-sparking drives are mandatory where fume concentrations have the potential to exceed half of the lower explosive limit b) Air supply shall be fit for the purpose, free from contamination and of sufficient pressure and volume for the job. c) Regulators and gauges shall be provided for the air supply to the pump and pressure pot and the air supply lines shall be fitted with efficient oil and moisture traps.
  • 63. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 63 of 92 C5.7 QA/QC template Paint inspection record Project: Engineer witness: Contractor: Sign-off Inspector/supervisor: Sign-off Coating specification reference: Items inspected Substrate Coat 1 Coat 2 Coat 3 Coat 4 Date/Time % RH Climate Air Temp Data Dew Point Surface Temp Date/Time Surface Cleanliness Preparation Profile Type Paint/ Date/Time Application Batch Number Mixing Thinning Date/Time W.F.T Number Min Coating D.F.T Max Inspection Average Std Dev Holiday Appearance Comments:
  • 64. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 64 of 92 C6. Demolition and abandonment C6.1 General Demolition includes the removal of structures or facilities as well as the safe abandonment of below ground structures and pipelines. Work shall be conducted efficiently and safe in a manner that prevents damage to infrastructure and the environment. C6.2 Existing work and damage a) The structure to be demolished shall be inspected and the demolition method produced. Where available the contractor shall study the structure’s drawings and specifications. b) Where underground pipelines and structures are to be abandoned and filled, the inspection shall identify defects that may compromise the filling activity. C6.3 Protection of people, property and environment a) . A pre-condition survey shall be done on surrounding infrastructure and utility locations identified before any demolition activity commences. b) Damage to other structures shall be repaired by the contractor to the original condition c) Explosives shall not be used for demolition works. d) Adequate support and shielding shall be provided to protect existing structures, the environment, the public and any other person. e) Abandonment of structures and the infill material to render the abandoned structure safe shall unless otherwise specified, consider the following requirements, to be accepted by Watercare: • Short and long term environmental affect i.e. current service condition (damage, joint type), delayed deterioration of the host, etc. • Risk of future collapse • Risk of future development over an abandoned structure i.e. housing • Location of the service i.e. coastal marine, underground aquifers, fissures or underground drains, ground conditions, location to streams, service depth and structural loading • End cap and filling point design as well as tie-off requirements at completion that is appropriate to the product being used • Product shrinkage and the risk impact it will have on the structure in its location on either failure or leaching C6.4 Removal of material All material and other rubbish generated by demolition activities shall be removed to an appropriate tip site. C6.5 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Preparation Facility plans and specifications Required Required N/A 2 Utility service plans and mark-outs Required Required N/A 3 Pre-condition survey Required Required N/A 4 Site management Demolition plan Required Required Required 5 Abandonment Methodology and product approval Required Required Required 6 Material removal Appropriate tip site dockets Required Required As specified Sign-off C7. Masonry C7.1 Workmanship Registered masons or tradespeople under the direct supervision of a registered mason shall be used for masonry construction. A registered mason shall be on site at all times during masonry construction work.
  • 65. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 65 of 92 Masonry to carry temporary loading shall be certified by a chartered structural engineer. The certification shall be forwarded to Watercare for acceptance. C7.2 Materials handling and block types a) Damaged blocks shall not be used. b) Unless shown otherwise blocks for 200 walls shall be open ended web bond beam type blocks type 20.16 except at wall ends which shall be lintel blocks type 20.12 alternating with type 20.13. c) Use inverted series 20.16 for the first course. d) Where shown on architectural drawings, use rebated blocks type 20.11 and 20.13 for window jambs and where detailed. e) For window heads use type 20.08 sill blocks where detailed. f) Type 20.16 blocks shall not be positioned with webs adjacent to each other. C7.3 Laying of masonry a) Cutting of blocks shall be avoided as far as practicable. Particular care shall be taken in cutting blocks for mitre joints to ensure straight neat edges are achieved and even 10mm mortar joints obtained. b) Unless specified otherwise, lay all blocks in running bond. Blocks shall be laid true to line, plumb and level with the thicker end of the shell up in mortar courses. c) All joints shall be in complete contact with mortar after bedding in. Masonry in construction shall be stabilised as necessary without compromise to the structural integrity to prevent any lateral force that may topple the construction. d) All joints shall be tooled appropriately where exposed to view forming sharp, clean lines and compact right joints. Unless specified otherwise all joints shall be formed to a concave shape using a proprietary tool. e) After laying, the mortar shall be prevented from drying too rapidly in hot dry weather by applying a very light fog spray several times during the first twenty-four hours. f) `Knock-ins' shall only be used on approval. The knock-in shells shall be placed so as not to protrude into the flue to be grouted and yet prevent any grout loss into flues to be unfilled. g) Allow for building in all bolts, fixings, ties, joinery pipes, flashings and all other embedded metal work, hardware and all conduited, boxed and wired services as may be required by this and other trades. Only the block layer shall carry out whatever cutting is necessary and all patching and making good required after the other trades have completed their work. h) In exposed blockwork, cut-outs shall be symmetrically placed in the block. Cut-outs shall not be visible after the fixing of cover plates. i) The block layer shall ensure that positions of reinforcement starters, rebates etc. are located accurately to suit the blockwork. j) The starter bars should be checked for position before laying the first course of blockwork. k) If the starter bars are incorrect then work shall only proceed with written approval. Double cranking of starter bars to align with continuing steel is not acceptable. C7.4 Clean-out ports a) Provide clean-out ports in the bottom course of all high-lift and other walls where cleaning of mortar droppings and debris is not possible by other acceptable means. b) Use inverted series 20.16 blocks for the first course to each grout lift. Ports shall be a minimum of 200mm high by 100mm wide. c) Locate ports at each vertical reinforcing bar position on the wall side, with least visibility. Remove full block face shell and after grouting replace to align with wall face and to form even joints to match existing. C7.5 Control joints a) Reinforce and grout vertical cores to both sides of joints. Control joints shall be sealed with 10mm x 10mm minimum section of grey colour "Thioflex" or approved equivalent, applied to the clean dry joints according to the supplier's instruction. Before caulking, rake out to 20mm depth. b) The sealant shall be applied full height both sides of control joints and using masking tape both sides of joints to prevent marking of exposed walls. Remove the tape after the surface has become firm. Shape the sealant to match mortar joints.
  • 66. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 66 of 92 C7.6 Reinforcement a) Reinforcement shall be as shown on the specific drawings except that links, stirrups and ties shall not be less than Grade 300 plain round bars. b) All masonry cells shall be solid grout filled. Compaction shall be by rodding or vibration. C7.7 Filling cores All grout spaces shall be cleaned out and the mortar joints reached sufficient strength before commencing with grout pour. C7.8 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Qualification Registered mason(s) Required Required Required 2 Material inspection Block without defects/unbroken N/A Required As specified 3 Joints 10mm even mitre N/A Required As specified 4 Reinforcing As per drawings and min Grade 300 for links, stirrups and ties. N/A Required Required 5 Test mortar Min. 3x successive samples at start (min 1 per day). NZS 4210 Appendix 2 Required Required N/A 6 Grout spaces cleaned Visual inspection N/A Required As specified 7 All cores filled Visual inspection N/A Required As specified Sign-off C8. Plumbing C8.1 General a) This section covers general domestic or similar type installations. Work shall be carried out to meet the requirements of the Building Regulations 1992 (SR 1992/150) – Section 1. Work shall be carried out by persons authorised under the Plumber, Gasfitters and Drainlayers Act. b) Preparatory work including supporting structure, framing and sleeved or formed openings shall be inspected before work commences and any defects immediately made good. c) Galvanised steel pipe buried in the ground or in concrete shall have oil and grease removed by solvent washing and then wrapped with an accepted corrosion protection tape. Tape width shall be applied to give 50% overlap. d) Runs shall be to even grades and fixed with collars and supports of appropriate materials to suit the pipes. Supports shall be regularly spaced to provide full support and prevent movement and deflection. All bends shall be sweep bends or easy right angle bends. Elbows shall not be used. At ends of horizontal pipe runs and at changes of direction of waste pipes suitable inspection and clearing points shall be included as required by regulations. e) Exposed wastes and vents shall be fixed 40mm clear of wall surface using stand-off brackets. Pipes and vents passing through walls and roofs shall be neatly and completely weathered. Wrap pipes with an accepted protective tape, where passing through concrete slabs or walls. Where possible all pipework shall be concealed in walls, ceilings, floors, and ducts or as otherwise shown on the specific drawings. f) To prevent electrolytic action, dissimilar materials shall be separated by suitable inert materials as interlayers, sleeves or as applied impervious coatings. g) Fixings including nails, screws and bolts shall be fully compatible with and/or of similar materials as the work being fixed and resistant to corrosion. h) After completing leakage tests the system shall be flushed with potable water from the highest point at minimum 1m/s flow velocity until the water is running clear.
  • 67. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 67 of 92 C8.2 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Qualifications Registered as authorised Required Required N/A 2 Pipework inspected Pipe wrapping Dissimilar materials isolated Directional change with sweep bends N/A Required Required 3 Test Gravity – leakage test for non- pressurised pipes. Water – pressure tested for plumbing works (see section 10). No leaks Required Required As specified 4 System flushed Water running clear N/A Required As specified 5 Certificate of Code Compliance As per the Building Act 2004. Required Required Required Sign-off C9. Carpentry C9.1 Workmanship a) All timber shall be worked and cut to a proper contact fit in accordance with best trade practice. b) All connections shall be accurately made and properly executed to provide sound connections for the class of work required. In exposed work all nails shall be well punched and screws adequately countersunk to allow for finishing with stopping work. c) All framing shall be fixed true to line, plumb and square and/or to the plan profiles. The maximum tolerance from plane to plan profiles shall be 6 mm in 3 m measured from a straight edge or template. d) Joinery fittings shall be shop manufactured. All work shall be free of defects. All exposed exterior work shall be machine finished. All hammer marks shall be removed. All timber exposed to view shall be dressed and sanded smooth. e) All floors shall be sanded to a smooth finish to line level and profile fully compatible with the finish to be applied. f) The checking and cutting of timbers and framing shall be reduced to a minimum and checking shall be replaced with bored holes where possible. g) The checking of plates and studs shall be less than 15 mm for 75 mm members and 25 mm for 100 mm members. Holes drilled through the centres of members in lieu of checking as above may be to 25 mm diameter and 35 mm diameter respectively. h) Beams and joists shall not be notched or holed on their edges at any point closer than 600 mm to the end supports. Holes shall be drilled only along the neutral axis. Holes or notches shall not exceed 1/5th of the depth of the beam or 30 mm diameter or edge dimensions whichever is the lesser. C9.2 Fasteners and fixings a) Electro plated fixings are not permitted. b) Screws shall be of steel unless otherwise specified and of suitable gauge and length to ensure adequate fixing. c) Fasteners or fixings where exposed to the weather, or in damp conditions, or through cedar or redwood shall be galvanised steel, brass, copper or stainless steel. d) Finishing nails shall be suitable for the class of materials to be fixed. C9.3 Timber treatment a) Unless otherwise specified, the minimum standard of treatment shall be grade H3.1 in accordance with NZS 3602. b) Fixing to concrete work shall be made by screwing; nailing or dovetailing using H4 classification treated pine or approved plastic grounds. c) Machine stress graded timber to MSG10 in accordance with AS/NZS 1748 shall be used for all roof and floor framing.
  • 68. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 68 of 92 C9.4 Timber sizes a) All framing timbers unless specified otherwise shall be machine gauged four sides. Dressed timbers shall be to the finished sizes shown on the specific drawings. b) Other timbers shall not be dressed or thicknessed or cut down by more than 10 mm below the nominal size. C9.5 Framing a) Linings shall not be fixed until the framing and preparatory work has been checked to ensure proper alignment. b) Linings shall be fixed true to line, plumb and square and straight and flat to plan profile. c) The maximum tolerance from plane to plan profile shall be as follows: • Gradual Irregularities: 6 mm in 3m measured from a straight edge or template • Abrupt Irregularities are not permitted C9.6 Moisture content a) In addition to the requirements of NZS 3602, all finishing timbers and strapping for linings shall be dried to a moisture content between 8% and 13% and shall be kept dry at all times. Timber showing signs of faulty or excessive kiln drying shall be rejected. b) Framing timbers shall be reasonably dry when erected and shall have dried to moisture content of between 16% and 20% before internal linings are applied. Framing timbers exposed to view shall be dried to less than 16% moisture content. Finishing timbers in areas shown to be air-conditioned or to be heated by a central plant shall be dried to less than 10% moisture content. c) Moisture contents specified above shall be based on oven-dry weight. C9.7 Material handling a) Framing timbers stored on the site shall remain bundled until required for use and protected from moisture, contamination, and excessive sun exposure. b) All joinery and dressed timbers shall be completely protected from the weather, contamination, and damage for the duration of the work. C9.8 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Material storage Dry, not exposed to elements N/A Required As specified 2 Timber type H3.1 to NZS3602 (H4 where fixed to concrete); MSG10 to AS/NZS1748 for floor and roof framing Required Required As specified 3 Fasteners No plated. Required. Required As specified 4 Measure wood moisture content General 16%-20% Heated functional area <10% Required Required Required 5 Inspect framing Irregularities less than 6mm in 3m Framing fixed to concrete H4 grade N/A Required As specified 6 Cutting and jointing Within limits of workmanship requirements. N/A Required As specified Sign-off C10. Metal roofing C10.1 General a) All material shall be new and free from defects, damage or dirt. b) The type, class, gauge and profile shall be as per the specific drawings. c) Underlay shall be breather type and waterproof.
  • 69. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 69 of 92 d) Nails, screws and fastenings shall be in accordance with the roofing manufacturer’s specifications and comply with the relevant aspects of NZS 3604. e) Accessories, capping, flashings and fixings shall match the metal roof type and be in accordance with the roofing manufacturer’s requirements. C10.2 Execution of work a) Roofing and accessories shall be stacked on clean, level areas of the site and protected from damage and weather until ready to fix in place. b) The roof structure shall not be overloaded when roofing materials are placed on the roof area prior to installation. c) All installation shall be undertaken by commercial installers, certified by the roofing material manufacturer or other approved experienced and competent roofers familiar with the roofing material to be installed. d) Clean soft-soled shoes shall be worn by the roofing installers whilst walking on coated roof surfaces. e) Installation shall be in accordance with the requirements in the NZ Metal Roofing Manufacturers Inc: “NZ metal roofing and wall cladding code of practice”. C10.3 Joints a) All fixings shall be made strictly to the manufacturer's recommendations and/or as shown on the plans or specified in the schedule. b) Any welding shall be carried out by specialist welders experienced in the class of work required. c) Expansion joints shall provide full weather tight laps in addition to allowing temperature movements. The contractor shall allow for all special fittings, gaskets and fixing to expansion joints. d) Suitable barriers between dissimilar metals shall be provided to prevent electrolytic action and corrosion as recommended by the manufacturer. C10.4 Capping, flashings and other hardware The contractor shall provide and fix all the necessary flashings and over-flashings to completely weatherproof the roofing. C10.5 Damage and performance a) Visibly bent, dented or heavily scratched roof sheeting shall be removed and replaced. Scratches to the colour coat that have not penetrated to the base metal and is visible to less than 1% of the sheet surface shall be left as is. b) The contractor shall provide a written guarantee of water tightness for a period of five years from the completion of the work. C10.5 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Material per drawings Gauge as specified. Material certified to NZS 3604 N/A Required As specified 2 Material inspected for defects No bends, no dents & scratches <1% of total area. N/A Required As specified 3 Installer certified Required Required N/A 4 Joints inspected Dissimilar material isolated, weather tight N/A Required As specified 5 Guarantee provided 5 year certification Required Required N/A Sign-off
  • 70. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 70 of 92 C11. Polymer-type chambers C11.1 Approved chambers a) Chambers must be approved by Watercare for use with specific limitations on purpose and location suitability. Acceptable chambers are listed in the Watercare Material supply Standard. b) Where integral bases are not supplied with chambers, a concrete chamber floor shall be installed in accordance with section C4.2. c) Where chambers are not supplied with an approved lid, a concrete lid shall be manufactured in accordance with section C4.2. C11.2 Foundation The chamber shall be founded on a firm and stable base, with site concrete as required, to provide a clean working surface for construction of the chamber. C11.3 Penetrations a) Penetrations shall not be cut in areas, or of a size and quantity that may compromise the chamber wall integrity. b) Penetrations shall be cut by hole-saw. c) Penetrations shall be sealed against the pipe with an approved proprietary rubber sealing system. C11.4 Infiltration performance The sealing between all joints shall be with an acceptable material providing 100 year performance and installed to the manufacturer’s requirements. The sealing material shall meet the minimum infiltration test performance criteria applicable to the installation circumstances. C11.5 Backfill Backfill shall be in layers and of material as specified by the product supplier. C11.6 QA/QC template Quality / Control Measurement Certification Document supplied Site supervisor witness Engineer witness 1 Set-out Line and level in accordance with specific drawings N/A Required N/A 2 Foundation Inspected, sound/firm N/A Required As specified 3 Penetrations Hole-sawed to size with suitable rubber seal N/A Required Required 4 Vertical Survey Required Required N/A 5 Infiltration Applicable test per Section 10.5.2 Required Required Required 6 Roof slab/Lid HN-HO-72 certified (where constructed in road-way) Required Required Review document 7 Access lid Appropriate load class fitted Required Required Required Sign-off
  • 71. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 71 of 92 10. Testing This section prescribes the testing requirements for the various civil construction components covered in this standard. 10.1 Roading and development NZ Transport Agency: NZTA M10 Notes, Table N3.1, Design level 1. Standard and Optional tests apply. 10.2 Backfill compaction testing NZS 4402, Test 5.1.2 and 5.1.4. Testing shall be carried out by a NATA/IANZ accredited laboratory. 10.3 Installation of polyethylene pipe a) Pipe out of roundness and eccentricity tests as per dimensional tables in: AS/NZS 4130 Polyethylene (PE) pipes for pressure applications. b) Butt weld test by NATA/IANZ accredited laboratory to ISO 13953. Butt weld test methodology Butt welds shall be shown to be fully ductile by destructive testing. Weld samples shall be clearly marked with identifying marks and with the orientation of the weld in the welding machine. The testing laboratory shall be instructed to report test results with reference to the orientation of the weld in the welding machine. The weld beads shall not be removed for testing. In addition to the weld sample a section of unaffected pipe wall shall also be tested. The following shall be provided in addition to the test report specified by the testing standard: • Report the strength of each butt-weld test piece as a % of the strength of the unaffected pipe wall • A graph of load versus extension for all test pieces plus the specimen of unaffected pipe wall shall be plotted on the same axis – the plot shall record load and extension until there is complete separation of all the test pieces • Clear photographs of showing each test piece in elevation before testing • Clear photographs of the fracture surface of each test piece after testing • Observations and clear photographs showing anything unusual that may affect the test Butt-welds shall be free of visual defects. Unacceptable visual defects include: • Misalignment equal to or greater than 10 % of the pipe wall thickness • The bead is not fully rolled-over and symmetrical • The weld bead is not within the tolerances of POP003 • Pitting or bubbling in the weld bead • Discolouration of the weld bead • Inclusions or other obvious faults Where a butt weld has any of these visual defects it shall be considered unacceptable and shall be cut-out and replaced at the Contractor’s cost. Satisfactory completion of a hydrostatic pressure test shall not constitute acceptance of the butt welds. To be acceptable the butt weld shall: • Have a strength not less than 95% of the strength of the unaffected parent pipe, and • Be fully ductile. c) Electrofusion joint weld test by NATA/IANZ accredited laboratory to ISO 13954 d) Electrofusion saddle weld test by NATA/IANZ accredited laboratory to ISO 13956 e) Extremely thick walled electrofusion assemblies by NATA/IANZ accredited laboratory to ISO 21751
  • 72. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 72 of 92 Electrofusion joints and fittings test methodology Electrofusion socket assemblies such as couplers and bends removed for destructive testing shall have a minimum of 150 mm of pipe length either side of the socket. Tapping saddle samples for destructive testing shall have a minimum of one diameter of pipe either side of the tapping saddle or tapping tee. Weld samples shall be clearly marked with identifying marks. Electrofusion socket welds shall be free of the following visual defects: • Misalignment • Melt rise indicators not rising, or are unequal • Eruption of melt material past the melt rise indicator • Hand scraping (not allowed) • Depth of peel is less than 0.2mm deep • Mechanical scraping which does not extend past the area covered by the coupler (including area covered during assembly) • Witness marks not evident • Loss of melt material past the cold zone • Element wires extending past the cold zone Where an electrofusion weld has any of these visual defects it shall be considered not acceptable and shall be cut-out and replaced at the Contractor’s cost. Notwithstanding the visual appearance electrofusion welds shall be shown by destructive testing, to fail by ductile rupture of the weld plane. Less than 33% of the total fusion zone may be brittle. 10.4 Steel pipe weld band, socket and spigot joints – Pipe ≥700mm NB Refer to the Mechanical construction standard. 10.5 Pressure and leakage testing This specifies methods of tests and their application to field testing of pipelines and manholes for the purpose of determining acceptability. Field testing includes leak or hydrostatic pressure testing, as appropriate, for pressure and non-pressure pipelines and manholes. Field testing does not replace the test requirements of product standards. 10.5.1 Pipeline testing Note - The type of test shall be selected according to the application of the system and the type of material being tested. A) Non-pressure pipelines – Field leakage testing Leakage testing is used to reveal locations of potential infiltration and exfiltration due to the inclusion of damaged pipes, seals, or incorrectly made joints in the pipeline at the completion of installation. Leakage testing for acceptance of non-pressure pipelines shall be carried out by at least one of the following methods: A-1) Low pressure air testing; or A-2) Hydrostatic testing Note – Air tests provide qualitative data only, as air pressure losses cannot be related directly to water leakage rates. For pipeline test sections installed below the water table and for submarine pipelines, the test pressure used for the hydrostatic test and for the air test, shall be increased to maintain the required differential between internal and external pressure. A pipeline failing to meet the requirements of the air tests may be retested using the hydrostatic test method.
  • 73. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 73 of 92 A-1) Low pressure air test The test length shall be acceptable where the gauged pressure exceeds 18 kPa (or not more than 7 kPa less than the pressure at the start of the test) for the time interval shown in table A-1 after shut-off of the air supply. Table A-1 is based on an air test pressure of 25 kPa in excess of any external hydrostatic pressure due to groundwater and, on this basis air volume losses shall not exceed the greater of: a) A rate of 0.0009 m³/(min x m²) of pipe wall area; and b) A rate of 0.056 m³/min, which is regarded as the lowest detectable individual air leak c) Column 2 and column 3 of table 1 give the times and lengths up to which (b) prevails over (a) Note – For safety reasons air test pressures in excess of 50 kPa should not be applied. Table A-1 – Low pressure air and vacuum tests – Minimum time intervals for 7 kPa pressure change in pipeline DN Minimum time (minutes) Maximum length for minimum time to apply (metres) Test length (metres) 50 100 150 200 250 300 Minimum test duration (minutes) 80 1.5 231 1.5 1.5 1.5 1.5 1.6 2 100 2 185 2 2 2 2 3 3 150 3 123 3 3 3 5 6 7 225 4 82 4 5 8 10 13 15 300 6 62 6 9 14 18 23 28 375 7 49 7 14 22 29 36 43 450 9 41 10 21 31 41 52 62 525 10 35 14 28 42 56 70 84 600 11 31 18 37 55 73 92 110 675 13 27 23 46 70 93 116 139 750 14 25 29 57 86 115 143 172 900 17 21 41 83 124 165 207 248 1000 28 12 51 102 153 204 255 306 1050 20 18.8 56 112 169 225 281 337 1200 23 15 73 147 220 294 367 441 1500 28 12 115 230 344 459 574 689 NOTE – The time interval may be reduced for a proportionate reduction in the allowable pressure drop. Where there is no detectable change in pressure after 1 hour of testing, the section under test shall be deemed acceptable. This table is based on the following equation: T = 1.02DikLq where T = time for a 7 kPa pressure drop, in seconds Di = pipeline internal diameter, in metres q = allowable volume loss in cubic metre/minute/square metre taken as 0.0009 m3/min.m² k = 0.054DL but not less than 1 L = length of test section, in metres. Columns 2 and 3 have been calculated with k = 1.0. The appropriate air or vacuum test/pressure method for pipes larger than DN 750 should be established by reference to the specifier.
  • 74. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 74 of 92 Low pressure air test procedure The procedure shall be as follows: a) Pump in air slowly until a pressure of 25 + 5−0 kPa is reached. Where the pipeline is below the water table this pressure shall be increased to achieve a differential pressure of 25 kPa. In no circumstances should the actual pressure exceed 50 kPa; NOTE – Rapid pressurisation may cause significant air temperature changes, which will affect the testing accuracy. b) Maintain the pressure for at least 3 minutes. c) Where no leaks are detected, shut off the air supply. d) Where the pipeline fails the test, re-pressurise to 25 +5,−0 kPa and check for leaks by pouring a concentrated solution of soft soap and water over accessible joints and fittings. e) Repair any defects, then repeat steps (a) to (c). f) With the air supply shut off, monitor the pressure for the time intervals given in table. The test length shall be acceptable where the pressure drops by 7 kPa, or less, over the required (tabulated) test period. Note – (1) The test length of pipeline should be restricted to pipeline sections between maintenance holes (the most convenient places for inserting test plugs or fixing temporary bulkheads). The method should not be used for test lengths in excess of 250 m and for pipe diameters larger than 1500 mm. (2) The procedure for low pressure air testing of large diameter pipelines is potentially hazardous because of the very large forces to be resisted by temporary plugs or bulkheads and the serious consequences of accidental bulkhead blow-out. A relief valve, with a 50 kPa maximum setting, should be installed on all pressurising equipment. A-2) Hydrostatic test The test length shall be acceptable where the make-up water added is less than the specified allowable. Where not specified, the allowable make up water shall be 0.5 L/hour per metre length per metre diameter. Hydrostatic test procedure The procedure shall be as follows: a) The test pressure shall be not less than 20 kPa, or 20 kPa above the groundwater pressure at the pipe soffit at its highest point, whichever is the greater, and not exceed 60 kPa at the lowest point of the section. b) Steeply graded pipelines shall be tested in stages where the maximum pressure, as stated above, will be exceeded if the whole section is tested in one length. c) The pressure shall be maintained for at least 2 hours by adding measured volumes of water where necessary. d) Any visible leaks detected shall be repaired and the pipeline shall be retested. B) Pressure pipelines general requirements – Field hydrostatic pressure testing Hydrostatic pressure testing requires selecting an appropriate configuration of method, pressure, and length of test section. Compressed air testing shall not be permitted for pressure pipe. Test parameters and details shall be determined with due consideration to the following: a) Pipe material b) Pipe diameter c) Length of test section d) Duration of the test e) Magnitude of test pressure and rate of pressurisation f) Presence of air in the pipeline g) Time required for saturation of porous liners
  • 75. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 75 of 92 h) Potential movement of pipeline thrust restraints i) Design pressure for thrust and anchor supports j) Accuracy of test equipment k) Ambient temperature changes during testing l) Presence of leaks in equipment used for testing or equipment attachment points (such as sealing plugs) m) Potential for leaks in the pipeline B-1) Selection of test pressure The hydrostatic test pressure at any point in the pipeline shall be: a) Greater than the design operating pressure; and b) Less than 1.25 times the rated pressure of any pipeline component. Note – The design pressure is the maximum system pressure at a point in the pipeline, considering future developments, static pressure, dynamic pressure and an allowance for short-term surge pressure (water hammer), as determined by analysis. B-2) Selecting test lengths The pipeline length tested shall be either the whole or a section (capable of being isolated), of the pipeline depending on the length and diameter, the availability of potable water and the spacing between sectioning valves or blank ends. The pipeline shall be divided into test sections such that: a) The hydrostatic test pressure at any point in the pipeline: i. Shall be less than 1.25 times the rated pressure of the pipeline, but not less than the designed working pressure at the lowest pressure point (highest elevation point where pipe is tested on a sloped installation); and ii. Is less than 1.25 times the rated pressure of any pipeline component; b) Test sections shall be limited to pipe of the same material. Consideration shall be given to the pressure loading time at the maximum filling rate (see B-3) in determining the test length; and c) Water is available for the test together with facilities for its disposal, in accordance with regulatory requirements, after the test. Note - Watercare recommends that test sections be done as short as possible to reduce the efforts during fault finding should a test length fail to pass the test. The following should be considered: (1) Where long lengths are to be tested, radio or other electronic means of communication between test operatives to coordinate test procedures and thus minimise the test duration is desirable. (2) Long test sections may incorporate a large number of mechanical joints which should be checked for leakage. The longer the test section the harder it is to locate a leak or discriminate between a leak and other effects such as the absorption of air into solution under pressure. B-3) Pre-test procedures The pre-test procedures are as follows: a. All required temporary and permanent thrust blocks shall be in place, and all concrete shall be adequately cured (normally a minimum of 7 days). b. Blank flanges or caps shall be installed at the beginning and end of the test section. Testing shall not take place against closed valves. Mechanical ends that are not end load resistant shall be temporarily strutted or anchored, to withstand the test pressures without movement. c. Pipe ends shall be capped with suitable restrained end caps that will sustain the full test pressure. For steel pipe the Watercare standard test cap detail drawing shall be used. Note – Temporary supports should not be removed until the pipeline has been depressurised. All test personnel should be informed of the loading limits on temporary fittings and supports. d. Where practicable, all bolted joints shall be left exposed to allow for re-tensioning during or after testing.
  • 76. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 76 of 92 e. Compacted embedment and fill material shall be placed to leave all joints, service connections and ball valves exposed wherever possible. f. For PE pipelines, the pressurising time shall not exceed 45 minutes. Note – The pressurising time affects the duration of the PE pipeline test. g. The test equipment shall be placed in position and checked for satisfactory operation. h. The pump shall be of adequate size to raise and maintain the test pressure. Note – A pump that is too small may increase the test duration or where too large it may be difficult to control the pressure. i. Two calibrated test gauges shall be used to cross check gauge accuracy. j. Slowly fill the test length of pipeline with water, preferably from the lowest point, ensuring air is vented at the high point valves. Allow a period between a minimum of 3 hours and 24 hours (preferred), for the temperature of the test length and the test water to stabilise and for dissolved air to exit the system. The recommended rate of filling shall be based on a flow velocity of 0.05 m/s, calculated from the following equation: Qf ≤12.5πD2 where Qf = filling rate, in litres per second D = pipe diameter, in metres Note – The slow rate of 0.05 m/s avoids air entrainment when the filling water is cascading through downward gradients along the pipeline. The period of stabilisation will depend on pipe dimensions, length, material, longitudinal profile, and air exit points. For cement-mortar lined pipe, the pipeline shall be filled at least 24 hours before the commencement of the test, to allow the lining to become saturated. A firm foam swab may be used ahead of the fill water to assist air removal especially where the pipeline undulates. Extract the swab at a high-point wash-out. The swab must be removed prior to testing. Typical pressure test equipment and location are shown in figures B-4-1 and 2. B-4) Post-test procedures After testing, pipelines shall be depressurised slowly. All air venting facilities shall be open when emptying pipelines. The test water shall be drained to an approved waterway and all connection points shall be reinstated.
  • 77. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 77 of 92 Figure B-4-1 – Typical pressure pipeline under field hydrostatic test Figure B-4-2 – Typical field pressure test equipment layout (designed as appropriate to the test pressure)
  • 78. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 78 of 92 B-5) Constant pressure test (water loss method) – PVC, DI, GRP, and steel pipelines This test is applicable for PVC, DI, GRP, and steel pipelines. The procedure shall be as follows: a) Close all valves apart from the test pump input and pressurise the test length to the specified test pressure (STP) – (see B-2). b) Apply and then maintain the test pressure by the addition of measured and recorded quantities of make-up water at regular intervals over a period, in the range of 1 hour to 12 hours. c) Where pressure measurements are not made at the lowest part of the test length, make an allowance for the static head, between the lowest point of the pipeline and the point of measurement. The quantity of make-up water necessary to maintain the test pressure shall comply with the following equation: Q ≤0.14LDH Where: Q = allowable make-up water, in litres per hour L = length of the test length, in kilometres D = nominal diameter of the test length, in metres H = average test head over length of pipeline under test, in metres Note – The make-up water is not a leakage allowance, but is an allowance to cover the effects of the test head forcing small quantities of entrapped air into solution. Normally the test should last for a minimum of 2 hours and be concluded within 5 to 8 hours. The make-up water requirement should reduce with time as air goes into solution. Where, after 12 hours the make-up water still exceeds the allowable limit, testing should cease and the cause of loss investigated. Acceptance: a) The test length shall be acceptable where there is no failure of any thrust block, pipe, fitting, joint, or any other pipeline component. b) There is no physical leakage. c) The quantity of make-up water necessary to maintain the test pressure complies with the quantity calculation. B-6) Pressure decay test for PE pipe larger than DN200 or longer than 250m This test procedure is applicable to Polyethylene pipe of larger size and length or where larger water systems are being tested (up to 1000m). An alternative test is the static pressure test for PE pipe in section B-9). The procedure shall be as follows: a) Close all valves apart from the test pump input and pressurise the test length to the specified test pressure (STP) – (see B-2). The pressure loading time shall not exceed 45min. b) Once the STP is reached with the conditions met, the pipe line is isolated and pressure allowed to naturally decay. c) Pressure decay over time in viscoelastic pipe is an exponential form and expressed in a calculated ratio as follows:
  • 79. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 79 of 92 Take a first reading of pressure P1 at T1, where T1 is equal to the pressure loading time (TL). - Take a second reading of pressure P2 at 7TL. Let this be T2. - Take a third reading of pressure P3 at 15TL. Let this be T3. - To allow for this stress relaxation behaviour of PE pipelines, calculate the corrected values of T1, T2 and T3. • Calculate corrected T1: T1C = T1 + 0.4TL • Calculate corrected T2: T2C = T2 + 0.4TL • Calculate corrected T3: T3C = T3 + 0.4TL d) Calculate decay slope ratio (N) values • Calculate N1: 𝑁𝑁1 = (𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙1 − 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙2) (𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙2𝐶𝐶 − 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙1𝐶𝐶) • Calculate N2: 𝑁𝑁2 = (𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙2 − 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙3) (𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙3𝐶𝐶 − 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙2𝐶𝐶) Acceptance: • For pipe HDD drilled or with compacted backfill: N1 and N2 range within 0.04 to 0.05; or • For pipe without backfill or soil support (i.e. slip lines or above surface): N1 and N2 range within 0.08 to 0.10; and • There is no physical leakage. • There is no failure of any component, movement of permanent thrust block or temporary thrust restraint used for testing. • Should the test fail, after the problem has been repaired the test shall be redone completely. Interpretation of results: • For N below 0.04 there is a likelihood of air in the system • For N is above 0.1 indicates a leakage
  • 80. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 80 of 92 • Where N is above or below the range for the backfill type inspect the graph slope: o Gradual slope is acceptable and N value may indicate a trench obstruction or small amount of air. Can be accepted o An initial steep grade followed by a gradual slope indicates a pressure sensitive fitting or component that leaked under higher pressure but restored under lower pressure. Accept pipe but inspect fittings o A steep change in gradient indicates a leak. The pipeline cannot be accepted. B-7) Pressure rebound test for PE up to DN 200 This test is applicable to PE and ABS pressure pipelines up to typically 250m length or shorter as to allow rapid pressure reduction when bleeding the system for the rebound test. The test rig shall be a recently calibrated pressure transducer, data logger, and check pressure gauge that has a dial of at least 100 mm diameter and a pressure range that places the specified test pressure (STP) (see B-2) in the range 35% to 70% of the gauge’s full scale. The transducer and the check gauge shall read within ±5% of each other. If they do not agree within this tolerance, the equipment shall be recalibrated or replaced. Procedure: a) Prepare the pipeline in accordance with B-3) pre-test procedure. b) Make sure that all air is expelled before commencing with the test and that no air is introduced into the section being tested. c) Maintain the STP for 30 minutes by additional pumping as required. d) Check for obvious leaks. e) After 30 minutes at the test pressure, reduce this pressure rapidly by bleeding water from the system (<5min), to a nominal pressure of 2bar at the test gauge. f) Close the control valve and isolate the test section. g) Record pressure gauge readings at 5 minute intervals for 1 hour after isolation. The test length shall be acceptable if: a) There is no failure of any thrust block, pipe, and fitting, joint, or any other pipeline component. b) There is no physical leakage. c) The pressure rises and then remains static or slightly increases during the 1 hour period. d) This test may be reduced on approval from Watercare to 30min in the rebound phase where there is an operational need to bring the pipe into service quickly. e) If the pressure does not rise, or falls after an initial rise the test is a fail. f) Should the test fail, after the problem has been repaired the test shall be redone completely. B-8) Visual test for small pressure pipelines This test is applicable for small pipelines of all materials, less than 20m in length, and pipelines without joints other than the end connections (such as coiled pipe). The procedure shall be as follows: a) The test pressure (see B-2) shall be applied and the test section isolated by closing the high point air release valves and the pump feed valve. b) The test section shall be visually inspected for leakage at all joints, especially bolted joints, all fittings, service connections, and ball valves. c) Pressure gauges shall be checked to ensure that pressure has not fallen significantly indicating an undetected leak. d) Any detected leak shall be repaired and the section shall be retested. e) Where no leak is detected, high point air release valves shall be opened, the pipeline shall be depressurised to slowly drain the line into an approved waterway and all connection points shall be reinstated. The test length shall be acceptable where: a) There is no failure of any thrust block, pipe, fitting, joint, or any other pipeline component.
  • 81. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 81 of 92 b) There is no physical leakage. c) There is no pressure loss indicative of a leak. d) Should the test fail, after the problem has been repaired the test shall be redone completely. e) B-9) Hydrostatic pressure test for PE pressure pipelines This test is applicable for PE pipelines larger than DN200 and/or longer than 250m and as an alternative to the pressure decay test in B-6). The test method shall be as described by ASTM F2164-13. Procedure: a) The pipe to be tested shall be selected and prepared as per section B-1) to B-3) b) Allow the test section and test liquid to equalise to common temperature c) Initial expansion – gradually increase pressure to the test pressure. If leakage occur or the test pressure cannot be reached the pipe must be repaired before proceeding with the test. d) Add make-up water as required to maintain the maximum test pressure for 4 hours. e) Reduce the test pressure by 69 kPa and monitor for 1 hour – do not increase pressure or add make- up water. Acceptance: a) There is no visible leakage. b) The monitor period of 1 hour remains at steady pressure within 5% the reduced test pressure. 10.5.2 Manhole and chamber (concrete) testing The type of test shall be selected according to the performance requirement of the system, the type of installation methodology, ground conditions and Health and Safety risk factors associated with the installation. All manhole tests shall include 300mm of the connecting pipework with the lid fitted into place unless otherwise stated. A) Hydrostatic testing of concrete manholes This test may be used for manholes up to 3.5m depth and relies on obtaining a proper seal from the pipeline plugs to withstand the hydrostatic pressure. The limitation on this test is the un-uniform pressure distribution and the zero pressure at the top of the manhole will not sufficiently test the top seal of the lid. To test the top seal this test shall be supplemented with the visual check (smoke test) in Section 10.5.2 D) or the low pressure air test as per Section 10.5.1, A-1). The manhole shall be completely backfilled and interconnected pipework and manholes be vacated before starting the test. Pre-test procedure: Ensure that there is no entry into the connecting trench or any connected manhole associated with the manhole being tested. The manhole shall not be pressurised beyond the static pressure and the access hatch shall remain open. Procedure: a) Seal pipe or sleeve openings using properly sized or inflatable plugs. b) Completely fill the manhole to the top of the lid frame with water. c) Allow the filled manhole to soak for minimum 4 hours. d) Top up any water loss to the top of the lid frame during the soak period. e) Measure the water loss over every 1 hour for 8 hours. f) Empty the manhole and allow standing for 1 hour before doing a visual inspection for groundwater infiltration. Acceptance: The average quantity of make-up shall not be more than 0.3 litres per 1m diameter per 1m depth per hour. The post-test visual inspection shall show no evidence of groundwater ingress through any joint.
  • 82. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 82 of 92 B) Vacuum test The vacuum test creates differential pressure between the inside and outside of the manhole. This test shall be completed with the manhole completely backfilled and the lid in place. Procedure: a) Clean manhole thoroughly. b) Seal openings using properly sized or inflatable plugs. c) Connect seal plate to manhole opening. d) Draw vacuum of -254mmHg (or -338.6mbar) and isolate valves. e) Hold test time according to the manhole sizes as listed in the table below: Depth (m) Diameter (mm) 675 900 1050 1200 1350 1500 1800 2400 3000 Time (s) <2 11 14 17 20 23 26 33 39 45 3 14 18 21 25 29 33 41 49 57 3.5 17 21 25 30 35 39 49 59 69 4.3 20 25 30 35 41 46 57 69 81 5 22 29 34 40 46 52 67 81 95 5.5 25 32 38 45 52 59 73 87 101 6 28 35 42 50 53 65 81 97 113 6.5 31 39 46 55 64 72 89 107 125 7 33 42 51 59 68 78 97 115 133 8 36 46 55 64 75 85 105 125 145 8.5 39 49 59 69 81 91 113 135 157 9 42 53 63 74 87 98 121 145 169 9.5 46 58 69 81 94 105 129 153 177 10 49 63 74 87 98 113 139 165 191 f) Release the vacuum and remove the test gear and plugs. Acceptance: a) For the duration of the test the vacuum did not drop below -228mmHg (or -304mbar). b) There are no visible wet patches or “sweating” at any of the pipe penetrations, seals or riser joints. C) Infiltration test This test is completed by creating an external water column around the manhole that will force groundwater through any leaking joints. This method is recommended where manholes are over 3.5m deep or that can only be part tested using the hydrostatic testing method up to 3.5m depth. However the limitation on part testing
  • 83. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 83 of 92 to 3.5m is that the hydrostatic pressure shall be demonstrated to be higher than the groundwater pressure at the location of the joints being tested. The vacuum test procedure is preferred over this option. This test does not confirm the lid seal and shall be supplemented with the visual check (smoke test) in Section 10.5.2, D) or the low pressure air test as per Section 10.5.1, A-1). Procedure: a) Excavate or provide a shallow moat of approximately 500mm width around the circumference of the manhole and fill with water. b) A 32mm PVC sleeve is inserted into the ground adjacent to the manhole wall to 1m below the hydrostatic test depth. The bottom 1m of the sleeve shall be perforated to allow groundwater to enter the sleeve. c) The water in the moat is filled until the groundwater in the sleeve reaches the level of the water in the moat. d) The groundwater level is maintained for eight (8) hours. Acceptance: There are no visible leaks, wet patches or “sweating” at any of the pipe penetrations, seals or riser joints. D) Visual check (smoke test) This test shall only be conducted on manholes where the joints and pipe penetrations being tested have not been backfilled over and are visible for inspection of forced smoke leaking through defective seals. The limitation of this test is to manholes that are not located within a 100 year flood plain level and is suited for low risk shallow manholes only. Procedure: a) Seal openings using properly sized or inflatable plugs. b) Connect seal plate to opening of manhole lid with appropriate connection to introduce the smoke. c) Introduce smoke into manhole being tested according to the manufacturer’s recommendation. d) The smoke shall be introduced for a minimum of 5 minutes. e) Inspect joints for smoke leaks. Acceptance: There is no smoke leaking from any of the joints. 10.5.3 Manhole (plastic/GRP material) testing Manholes shall be tested twice: a) Off-site as a single unit at the manufacturer’s facilities according to industry best practice for the material being used; and b) On installation on site, fully backfilled and connected, and tested per the vacuum test described in Section 10.5.2-B). The material testing sheets shall be made available for record purposes; having undergone Watercare’s pre- approval of the product being installed. 10.5.4 Fluid retaining structures (process tanks, reservoirs, etc.) This section relates to the testing requirements for single layer fluid storage structures with no pressure applied other than the gravitational weight of the fluid retained. These tests are not for manholes or man access chambers. A) Concrete tanks The test is to demonstrate fluid loss of less than 0.05% of the tank volume per 24 hours period. The test should be conducted long enough to produce at least 15mm drop in the level. The leakage rate is proportional to the depth of water over the leakage point with leakage at the bottom of a tank generally contributing more to the total leakage than a similar defect at a higher level in the tank. For odd shaped tanks such as clarifier tanks the
  • 84. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 84 of 92 depth shall be expressed as a calculated equivalent depth when determining the minimum test duration time, in example: Conical structure: Determine equivalent depth (d) = (H2 x A + [(H1-H2) x A] /3) /A Determine test time = 0.015/(0.05 x (d)x∏r² ) = test days (round up) Where: H1 = maximum/full water depth H2 = side wall height A = area r = radius A further impact on leakage rate determination is the surrounding media of the tank where groundwater could push back on a leak. Unsupported wall structures may deflect. Open lids or ventilation and temperature changes may affect the test results and needs to be accounted for. Evaporation per hour: Eh = Ɵ A (Xs – X) Ɵ = (25+19 V) where V = velocity of air above water surface A = surface area (open to evaporation) Xs = humidity ration in saturated air Air Temp ᵒC Humidity in saturated air (Xs) 0 0.003767 5 0.005387 10 0.007612 15 0.01062 20 0.014659 25 0.019826 30 0.027125 X = average humidity ratio over test period Temperature expansion/contraction: ΔV = β Vo ΔT β = Volumetric temperature expansion coefficient (use 0.000214 for water) ΔV = change in volume Vo = volume of water ΔT = temperature change Pre-test procedure: a) The structure must not be backfilled; or b) Where backfill is required as part of the structural integrity design, it shall be ensured that the surrounding soil is not ground water charged. A monitoring bore(s) up to 500mm below the tank foundation shall be provided to monitor ground water levels. If groundwater is present it shall be removed before testing may proceed. c) Fill the tank with water whilst monitoring all outlet drains, connecting pipes and valves, structural joints, etc. for visible leaks. d) The structure shall be kept filled with water for minimum 3 days before testing may commence. H2 H1 d
  • 85. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 85 of 92 Procedure: a) Confirm positions for measurements from at least two locations 180ᵒ apart. On larger tanks it is best to spread locations 90ᵒ apart (for 4 locations) to allow for settlement. b) Measure test starting level. c) Measure test start water temperature at depths of 500mm below the water surface level and at 2m intervals to the full depth of the tank. d) Calculate test time required. e) Repeat measurement every 24 hours. f) Compute leakage rate over test period. Account for evaporation and temperature change. Where the tank top is sealed ignore evaporation rate. Where the temperature is measured to be constant between measurements, ignore affects. Acceptance: Average water loss < 0.05% of total volume per 24 hours of testing. B) PE, GRP, steel tanks The test is to demonstrate fluid loss of less than 0.025% of the tank volume per 24 hours period. The test should be conducted long enough to produce at least 15mm drop in the level. Follow the test procedures as for A) concrete tanks. The saturation period of 3 days as part of the pre-test procedures is not required. Acceptance: Average water loss < 0.025% of total volume per 24 hours of testing. 10.6 Potable water infrastructure disinfection Pipelines, tanks and reservoirs for potable water use shall be disinfected in accordance with Watercare’s Code of Practice for water reticulation disinfection. 10.7 Concrete – buildings and structures NZS 3109 to clause 9 by NATA/IANZ accredited laboratory. 10.8 Shotcrete A test panel at least 1200mm x 1200mm for each mix being considered, the same thickness as the intended structure, using the same construction equipment and for each shooting position to be encountered (i.e. slab, vertical and overhead sections). Provide in the test panel the same reinforcement as intended for the structure in at least half of the panel, to test for proper embedment of reinforcing steel. Sample four cores from the panels for testing at 7 days and 28 days. All cut or broken surfaces shall be dense and free from laminations and sand pockets. In addition to the concrete testing requirements of NZS 3109 clause 9, complete to NZS 3112 test two 50mm cores recovered from every 75m² of the actual construction. Tests shall be completed by a NATA/IANZ accredited laboratory. Complete ultrasonic or impact hammer test across the construction area to determine overall uniformity to the specified thickness. 10.9 Masonry NZS4210, tests per Appendix 2 of the New Zealand standard. 10.10 Testing of plumbing installations Hot and cold water pipework, fully installed; carry out a hydraulic test of 1.25 times the static head with a minimum of 1200 kPa for a period of 60 minutes. There should be no visible leaks and zero pressure loss.
  • 86. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 86 of 92 10.11 Timber moisture content NZS 3602, General 16%-20%. Heated installation functional area <10%. 10.12 Direct current voltage gradient (DCVG) coating defect survey for new steel pipelines 10.12.1 DCVG survey types Construction DCVG survey: conducted during the installation of a new pipeline. The survey shall be conducted as outlined in the approved construction management plan. This survey shall be undertaken with the probes positioned over the pipeline, after backfilling of the trench has occurred and prior to sealing the surface with either bitumen or concrete. As this type of survey will generally be done in shorter sections, particular care must be taken when determining chainages and marking of defects. Commissioning DCVG Survey: completed after installation and construction DCVG survey has been completed. Where the pipeline runs under a sealed surface such as concrete of bitumen, the survey shall be conducted with the probes positioned in a suitable electrolyte (such as soil) as close as practicable to the centre line of the pipe. Where the pipeline runs under a sealed surface, Watercare shall define whether the surface can be saturated with water, or holes must be drilled through the surface to provide suitable contact with the electrolyte. 10.12.2 Minimum qualifications Task Minimum Level of Expertise Field inspection and testing Corrosion Technician with minimum 2 years’ experience in corrosion testing including specific training and experience related to coating defect surveys on pipeline, under the indirect supervision of a Corrosion Technologist Analysis and approvals Corrosion Technologist with a minimum 10 years’ experience in corrosion testing including specific experience related to coating defect surveys on pipelines or Corrosion Technician under the direct supervision and with report review and approvals of a Corrosion Technologist. Proof of suitable qualification shall be provided to Watercare. 10.12.3 Testing 10.12.3.1 Visual inspection & preliminary tests Prior to undertaking the DCVG survey, the following inspections and tests shall be undertaken: a) Record the locations of all electrical earths in the survey report. b) Record locations of all sacrificial anode beds in the survey report. Note - Electrical safety earth beds, such as those installed for the protection of personnel and equipment and mitigation of low frequency induced (LFI) a.c. currents are not to be disconnected from the pipeline unless safe to do so. 10.12.3.2 Method The body of Australian Standard AS4827.1 – 2008 Coating defects surveys for buried pipelines Part 1: Direct current voltage gradient (DCVG) provides “normative” advice on coating defects surveys and may be used as an additional guide to testing. However this document supersedes AS 4827.1 when working on Watercare’s assets. a) Signal application Minimum test point swing is 1000mV. Lower strengths may only be used if it can be shown that a defect of 0.1% IR will be detected from the equivalent methodology. The DCVG survey signal may be derived from the installed CP system power supply or applied using portable transformer/ rectifier unit utilizing the system anode ground bed or temporary earth electrode.
  • 87. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 87 of 92 Should stray current have significant impact on the accuracy of measured defect IR signals, the sizing of defects shall be undertaken during the period when there is no stray current. b) Survey methodology Determining DCVG Signal Amplitude to Remote Earth At Test Points The procedure to determine the DCVG signal amplitude to remote earth at test point is as follows: i. Place 1 reference electrode at the base of the test point or other electrical contact point with the soil, while the second electrode contacts the test point or other properly cleaned electrical point in contact with the structure. The potential swing measured by this arrangement is the DCVG signal amplitude between the pipe and the base of the test point. ii. Measure the voltage gradient from the base of the test point to remote earth by placing 2 probes which are separated on the ground adjacent to the test pipes (unless it was already established that there is no defect causing a voltage gradient adjacent to the test point). These 2 probes are then moved perpendicular in convenient steps at 90 degrees to the pipeline route measuring potential swings until remote earth is achieved. The sum of all potential swings of each step is then calculated from the base of the test point to the remote earth. (NOTE: Well coated pipeline may have a voltage gradient from the base of the test point to remote earth that is negligible unless a coating defect is in close proximity). In most cases, the DCVG signal measured in step (i) will adequately represent the total DCVG signal amplitude at the test point. iii. The total DCVG signal amplitude at a test point or other connection point is the sum of (i) and (ii) c) Recording of defects All defects located during the coating survey shall: • Be sized to remote earth and the IR drop recorded in mV • Be marked by driving in a peg or by fluorescent paint where a peg cannot be used. • Defect information shall recorded that includes: o GPS location recorded in NZTM (datum 2000) map coordinates, to the accuracy levels described in the Watercare Data and asset Information standard. o Description of the location with reference to the pipeline length, house number, distance from driveway, and other reference details noted to facilitate future re-location of the defect. o Offset from pipeline if the defect could not be centred on the pipeline. A sample format is provided below: Defect Number Metreage GPS Coords East- North Description of Location IR (mV) Example: Defect Number Metreage GPS Coords East- North Description of Location IR (mV) - 0 2661231- 6491234 Test point swing. TP1 1500 1 103 2661789- 4m d/s of d/s edge d/way 200 Smith St 5
  • 88. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 88 of 92 6491456 2 622 2661756- 6491789 2m u/s of power pole 21 Brown Rd 7 - 850 2661900- 6491551 Test point swing. TP2 1200 d) Coating defect survey - % IR calculation Defect sizes shall be related in terms of %IR by calibrating the measured IR sizes (mV) at defects against the signal size (mV) calculated to exist at the defects’ location. The signal size shall be determined from the measured signal size relative at a suitable number of “calibration” points along the pipeline, and attenuation of the signal shall be taken into account between the “calibration” points. Details of the survey and assessment, including calculated defect sizes (%IR), signal size the electrode potential survey data, shall be reported to Watercare for approval and acceptance immediately upon completion of the survey. Upon determining the epicentre of the coating defect, a series of lateral stepped potential swings shall be measured, moving from the epicentre toward remote earth. Note that lateral potential swings decay exponentially from the defect and remote earth is located when the lateral DCVG signal amplitude in subsequent steps is negligible compared to the sum of potential swings to that location. The sum of the potential swings is the IR component over the line of the coating defect to remote earth (SOL) and will be used for calculating “ %IR ”. Figure 10.12-1 depicts how SOL is calculated. Figure 10.12-1: Sum of potential swings Hence, the series of lateral mV readings to remote earth is summed to obtain the SOL. This is defined by equation below:
  • 89. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 89 of 92 SOL = (V1 + V2 + V3 + V4 + V5 ) mV If a defect is located, the %IR is calculated as the IR drop between a point on the ground directly above the coating defect and remote earth, expressed as a percentage of the estimated signal amplitude between the coating defect and remote earth. This is shown by the equation below: %IR = (SOL x 100) / SCF Note – • Digital voltmeters (DVMs) are not sufficiently accurate to obtain the difference between the ‘on and off’ pipe-to-soil potentials. • The DVM’s sample rate and screen update may not be synchronised with the DCVG pulse. • To reduce error, use the same DCVG instrument for all readings for a given %IR calculation, unless an accurate calibration between instruments has been established. 10.12.4 DCVG survey procedures The application of the DCVG survey technique is as follows: a) The surveyor should walk above the centreline of the buried pipeline and place one probe electrode in front of the other in the soil. Probes should be moist to provide good contact with the electrolyte. This may require the application of water to the electrolyte if the soil is dry or the survey is conducted over a small concrete surface. Should the pipeline run under a sealed road or large concrete surface (such as car park or building foundation), Watercare shall approve the methodology. b) The probe electrodes should be separated approximately 1.0 to 2.0 metres parallel and above the pipeline searching for voltage gradients along the pipeline. If perpendicular probes are used, one probe should always be directly above the pipeline where achievable. c) The DC offset and range selector switch is used to bring any pulse onto the meter scale. d) If a pulse is seen on the meter scale, the direction of the metre indicator deflection is observed as it points toward the electrode that is closest to the coating defect, assuming the electrode closest to the defect is connected to the negative terminal of the voltmeter. Opposite connections will cause the indicator to swing the other way. e) As the coating defect is approached, the amplitude increases and then reverses when the coating defect is passed. (If using perpendicular probes, the maximum indication will be observed when the probe above the pipeline is directly above the defect. Reversal will not occur once the defect is passed, only a reduction in amplitude). f) When a reversal of pulse direction is observed, this indicates a coating defect has been traversed. The coating defect location may be identified by retracting slowly to where no pulse is observed. The coating defect epicentre then lies midway between the 2 probe electrodes, and is normally marked by a line on the ground. g) The surveyor turns 90 degrees to the pipeline and the null process is repeated. A second line is marked, and the location where the two cross is the coating defect epicentre. This location is directly above the actual coating defect. Note - Max spacing between measurements of 5m in rural areas. Depending on signal strength, drilling through tar-seal may be required to achieve a suitable contact with the electrolyte if a suitable swing is not achieved on the berm of the road. • All defect indicators are to be precisely located and recorded. Any indication too small to be precisely located is to be recorded against the meterage range where it was identified. • When surveying over concrete, the concrete shall be wetted to obtain a suitable contact for the probes. • During construction survey (where the pipe has not been connected) all dirt shall be cleared away from bare steel (i.e. uncoated pipe ends, weld plates, AV connections). • In areas with low swing, closer spacing between readings shall be used in addition to greater spacing between probes.
  • 90. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 90 of 92 10.12.5 Acceptance criteria The following coating performance acceptance / rejection criteria shall apply to all steel pipelines. Other criteria may be adopted by Watercare for other types of coating system subject to sufficient justification of alternative criteria. Watercare shall define the criteria to adopt for existing mains prior to beginning survey. a) All defect indications equal to or greater than 0.2% IR shall be excavated and repaired providing there is no evidence to indicate that the indications are associated with anodes, or electrical earth (defects at test leads should be excavated no matter the size, as these are likely to be shielded and have different metals). b) Defects less than 0.2% IR shall be subjected to the following assessments: i. If a defect measuring ~ 0.2%IR is excavated and shown to be a significant size, then the next largest shall be excavated to determine the actual size of the defect. This process shall be completed until Watercare determine that the defect is insignificant. ii. Where two or more defect indications are separated by a pipe spool length, at least one shall be excavated, inspected and repaired. If the first indication is found to be at a pipe weld joint the other defect(s) shall be excavated. iii. Should isolated defects of this size (less than 0.2%IR) be located they may not require excavation and repair subject to the following provision: If the specified over-the-line electrode potential survey indicates that a polarized protection level (free of IR component and other interference) of at least 100 mV more negative than the minimum protection criteria specified for the pipeline can be achieved at all points along the affected pipeline section with a total protection current not exceeding 50 mA per kilometre length of the pipeline. All the defects shall be recorded for future reference. c) Chambers with water, chambers without water- Where a defect is located at a chamber the Watercare shall advise the criteria to adopt. Tees, joints, welds, cadwelds: - All defects located at Tees, joints, welds and cadwelds must always be repaired 10.12.6 Re-test following defect correction Following rectification of coating defects, details of repairs to the coating and subsequent performance measurements indicating the success of the repair shall be recorded on the pro-forma and supplied to Watercare for retention. All repairs are to have a DCVG carried out following backfill (this may be carried out after the pipe has a minimum of 300 mm cover). It is advised that the pipe either side of the excavation be DCVG tested while the defect being inspected is exposed, to ensure that no defects exist immediately up or downstream of the excavation that may have been shielded by the defect being inspected. The following table shall be used for recording corrected defects.
  • 91. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 91 of 92 Logging of defects and repairs: Defect Number Metreage (m) GPS Coords Description of location IR (mv) %IR (I)nspected/ (R)epaired/ (N)ot Repaired Description of defect Likelihood of shielding (H)igh (M)edium (L)ow Photo Number/ Name Date Inspected/ Repaired DCVG Survey
  • 92. Ver.1.1 This is an electronic ESF document that is uncontrolled when copied or printed Page 92 of 92 10.12.7 Report All test results shall be recorded and a separate report supplied to Watercare for assessment and acceptance prior to undertaking commissioning of the CP system for the pipeline. A record of defects shall be submitted to the Watercare for review following the assessment against the acceptance/ rejection criteria and a recommendation for proposed remediation where required to meet the criteria. The report shall contain the following as a minimum: a) Pipeline details including route length, diameter, fittings, off-takes, safety earths, sacrificial anodes and CP system components b) Details of equipment and methodology including method and location of signal injection points and strength of signal c) Potential survey results including output current and voltage of the direct current (CP) power source d) Listing of all coating defects located including reference points and GPS identification e) Where specified in this document, size of defects in term of lateral IR, signal size at calibration points, and calculated defect size represented as %IR f) Assessment of defect %IR sizes against the acceptance / rejection criteria in this document g) Recommendations for excavation, physical sizing and repair of defects h) Provide details of repairs undertaken and subsequent coating survey results indicating the criterion has been satisfactorily achieved. i) Photo record of defects during repairs 10.13 Mortar rehabilitation (lining repair) Samples and tensile bond strength tested to AS1012 part 24.