SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORKS

First Edition: May 2007

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J - DUCTILE IRON PILLAR HYDRANTS


1.0 General

1.1 This specification briefly specifies the requirement for the standard 100mm and 150mm
pillar hydrants.

1.2. Pillar hydrants will be of ductile iron material conforming to BS 750 : 1984 or JKR
Specification 202000-0042-99.


2.0 Type of Pillar Hydrants

2.1 100 mm diameter Pillar Hydrant

The 100 mm pillar hydrant shall be designed with 65 mm diameter outlets as shown
in Appendix 1 & 2.

The pressurized 100 mm pillar hydrant shall be equipped with landing valves as in
Appendix 3.

2.2 150 mm diameter Pillar Hydrant

The 150 mm pillar hydrants is provided with two 65 mm diameter outlets and one
100 mm diameter outlet as in Appendix 4.

The pressurized 150 mm pillar hydrant is equipped with two 65 mm diameter
landing valve and one 100 mm diameter outlet in Appendix 5 & 6.


3.0 Materials

3.1 Body and Cap: -

The body and cap of the pillar hydrants shall be made of ductile (spheroidal graphite) iron at least
of quality conforming in all respect to the requirements specified in BS 2789:1985 of Grade
421/12.

3.2 Outlets

The material for outlets shall be made of die-cast brass which must comply with the
standard BS 1400 Grade DCB1 with minimum tensile strength of 210 N/mm.

The screwed outlets shall be provided with caps to cover the outlet thread.

SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORKS

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The caps shall be securely attached to the hydrant by galvanized steel chain.

A minimum 3 mm thick rubber gasket conforming to BS 3457 shall be provided.

The screwed outlets shall be locked to prevent theft by using pins as shown.

3.3 Landing Valve: -

The materials used for all the components of the landing valve are as shown and must comply with
BS 5041 Part :1987.


4.0 Dimensions

4.1 Body

4.1.1 100 mm Pillar Hydrant

Overall height 827 mm 10 mm

External diameter of hydrant 130 mm 5 mm

Internal diameter of hydrant 102 mm 2.0 mm

Flange at inlet as specified in Table 11 BS 4504 1989 Section 3.2 for Ductile Iron.


4.1.2 150mm Pillar Hydrants

Overall height 875 mm 10 mm

External diameter of hydrant 213 mm 3 mm

Internal diameter 150 mm 3 mm

Flange at inlet as specified in Table 11 BS 4504 1989 Section 3.2 for Ductile Iron.


4.2 Outlet

4.2.1 65 mm diameter Outlet

This outlet is used as the standard outlets for the 100 mm diameter pillar hydrant and as the
side outlets of the 150 mm diameter pillar hydrant.


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4.2.2 Outlet diameter

Internal 64mm + 0.0 mm
- 1.5 mm

External 75 mm + 0.8 mm
- 0.0 mm

Length of outlet 122 mm 1.0 mm

Thickness of flange 10 mm 1.5 mm

Diameter of flange 96 mm 1.0 mm

Length of thread 35 mm 1.0 mm

Diameter of thread 35 mm 0.4 mm
(External)

Type of threads V - Threads

Threads per 25.4 mm 5 1/3 Nos

4.2.3 100 mm diameter Outlet

For the front outlet for all 150 mm diameter pillar hydrants required dimensions are
as follows: -

(i) Outlet Diameter
Internal 95 mm + 0 mm
- 1.5 mm

External 112 mm + 0.8 mm
- 0 mm

(ii) Length of Outlet 126 mm 1.0 mm

(iii) Thickness of Flange 12 mm 1.5 mm

(iv) Diameter of Flange 140 mm 1.0 mm

(v) Length of thread 50 mm 1.0 mm

(vi) Type of threads Round Threads

(vii) Threads per 25.4 mm 3 Nos.
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4.2.4 Landing Valves

All landing valves shall comply with BS 5041 Pt 1:1987 to be used for the pressurized
100mm pillar hydrant as well as the side outlets of the pressurized 150 mm pillar hydrant.

4.3 Caps

Cap dimension are as follows:

4.3.1 Cap for 65 mm diameter Outlets

Width of cap 42 mm 1.0 mm
External diameter of cap 100 mm 2.0 mm
Internal diameter 81 mm 0.5 mm
Rubber gasket Min. 3 mm thick


4.3.2 Cap for 100 mm diameter Outlet

Width of Cap 51 mm 1.0 mm

External diameter 210 mm 3 mm

Internal diameter 112 mm 0.5 mm

Rubber gasket Min. 3 mm thick

4.4 Chain

Material to be of galvanized steel.

Minimum diameter for the link of the chain shall be 5 mm.

The total minimum length of chain used for 100 mm pillar hydrant.

150 mm pillar hydrant shall be 660 mm and 1160 mm respectively.

Link of galvanized steel chain can be fixed either by attaching to the ear with a 100
mm drill hole or embedding in lug formed in casting.


5.0 Coating

5.1 All machined surfaces shall be thoroughly cleaned and shall be treated with a protective
composition before they become affected by rust.

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5.2 The outer surface of the body shall be coated of either fusion bounded epoxy powder or
approved fire hydrant yellow with minimum thickness 250 m conforming to AS / NZ
4158.

6.0 Testing

6.1 Hydrostatic Test

The hydrant is subjected to a hydraulic pressure of not less than 24 bar for a period of not
less than 24 bar of a period of not less than 1 minute.

Overall Flow Test

The hydrant shall deliver not less than 210 liters / min at a constant pressure of 1.7 bar at
the inlet to the hydrant (Results may be obtained by interpolation by referring to the
pressure versus flow curve as in Appendix 7).


7.0 Markings

Each hydrant shall have the following markings in raised letters of minimum 50 mm high cast on
the body.

The Manufacturers name and trade mark
The size of the hydrant
The year of manufacture (last two digits)
The word SYABAS
The body material identification DI
Made in Malaysia

8.0 Accessories

8.1 Accessories and fittings associated to pillar hydrants are: -

Double-flanged duck-foot 90 () bends
Pipes with cast-on flanges, Class K12
Valves
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8.2 All fittings such as double-flanged duck-foot 90 () bends and pipes with cast-on flanges,
Class K 12 connecting to the pillar hydrants shall be made of ductile iron.

8.3 All ductile iron fittings shall have the tensile strength of 421 Mpa and minimum elongation
of 5%.

8.4 Coating for fittings (both internally and externally)

All fitting shall be coated with fusion bonded epoxy powder of not less than 350 m
thickness.

All bolts, nuts and washers made of hot dipped galvanize zinc plated carbon steel
coated with Rislan Nylon with the finished thickness of coating between 75 m and
125 m.


9.0 Flanged joints

9.1 The dimensions and tolerances of the flanges of pipes and fittings shall comply with PN 16
requirement for ductile iron.

9.2 Each fitting shall be supplied with a set of flange jointing materials, which shall be
completed with nuts, bolts, washers and joint rings.

9.3 Joint rings shall be of flat section 5 mm thick, medium rubber reinforced with two-ply
flexible fabric and shall not extend beyond the bolt circle.

10.0 Pre- Delivery Inspection and Evaluation

10.1 It is the responsibility of the Contractor to inform SYABAS Sdn. Bhd. for inspection purposes
during manufacturing and before delivery.

10.2 SYABAS reserved the rights to inspect and witness the testing of product offered.

10.3 At any time, when requested, the Contractor is to provide SYABAS a sample of the product
offered for evaluation purposes. All costs shall be borne by the Contractor.

10.4 If at any time the Contractor fails to deliver the required sample, the product is deemed fail
to meet the specifications.


11.0 Certification

11.1 The Contractor is required to provide a copy of the certificate and testing report from SIRIM,
IKRAM or other recognised certification body.

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11.2 Tests report required should be those tests conducted within a year period.

11.3 SYABAS reserved the rights to refuse offer or reject supply if the documents required are not
enclosed.


12.0 Packaging

All pillar hydrants shall be individually packed with proper methods and protected from damage
during transit.




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SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORKS

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Appendix 5
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Cold Applied High Solid Liquid Epoxy Coatings
On Casting Surfaces (Both Internally and Externally)


1. Surface Preparation

All surfaces to be coated shall be clean and dry and free from porosity, crack, sand, rust,
oil, grease and other foreign matter. They shall be prepared by abrasive blast cleaning to Sa
2 Standard (ISO 85011). Only dry abrasive blasting procedures shall be used.

Any clean surface left overnight without coating shall be reblasted before application of
coating. In the event rusting occurs after completion of surface preparation due to bad
weather, the surface shall again be cleaned in accordance with the specified standard.
Cleaning shall be discontinued each day in sufficient time to permit the surfaces cleaned to
be coated before rust booming.

2. Coating Application

Coatings shall be applied in accordance with Section 3.3 of AWWA C210-84. Application
of coating shall be by spraying to a total dry film thickness of more than 356 microns but
less than 635 microns.

The coating shall not have coating imperfections such as blisters, cracks, bubbles,
underfilm voids, mechanical damages, holidays, pinholes or discontinuities.

3. Coating Repair

Areas requiring coating repairs due to coating imperfections shall be cleaned using hand
and power tool to minimum St 2 Standard (ISO 8501-1). The adjacent coating shall be
roughened. All dust shall be wiped off.

Same coating material shall be applied to the prepared repair areas immediately to the
required thickness. Repairs shall be electrically inspected using a holiday detector.

4. Coating Procedure

a. Coating System 1 (one) coat system

b. Application Condition :


SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORKS

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Surfaces shall not be coated in rain, wind, fog, mist or in areas where airborne elements
exist; when the steel surface temperature is less than 3
0
C above dewpoint; when the
relative humidity is greater than 85%. Blast-cleaned surfaces shall be coated as soon as
practical, not later than rust booming.

c. Paint Application Procedure :

Mixing, pot life, thinner shall be as per paint manufacture recommendation.

Apply a wet coat in even parallel passes. Overlap each pass 50% to avoid bare
areas pinholes or holidays.

Thinning normally not required. Thin only for workability with not more than 10%
by volume of thinner.

Check thickness of dry coating with non-destructive dry film thickness gauge.

In confined areas, observe safety rules provided by paint manufacturer.

Uncured paint should not be exposed to water, chemicals or mechanical stress
before the paint is fully cured.

It is recoatable provided that the existing surface is cleaned from oil or other foreign
contamination. Prior to recoating all irregular surfaces are to be sand paper abraded.

For multicoat system, recoating time shall follow paint manufacturer
recommendation.

Prior to recoating, all irregular surfaces are to be sand paper abraded.

5. Inspection

a. Surface Preparation :

Visually (From ST2 to SA 2.5)

b. Surface Profile :

The profile height shall be spot checked with Elcometer Profile Gauge or Keane-
Tator Comparator with reference to5a. above.

c. Paint Material
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Record batch number

d. Metal Temperature

The magnetic metal temperature gauge should be used. Metal temperature must be
3
0
C above the dew point.

e. Wet Film Thickness (WFT)

The comb-type gauge shall be used.

f. Dry Film Thickness (DFT)

The Elcometer DFT Gauge shall be used.

g. Visual Inspection

Coats shall be smooth, free from dry spray, pinholes, blisters, craters and excessive
sagging.


6. Testing on Applied External and Internal Coating

6.1 Holiday Test ASTM G62-87

All pipes shall be checked for continuity of the applied protection in accordance with
ASTM G62-87. Discontinuities and pinholes indicated by the test shall be made good as
per the manufacturer recommendation.

6.2 Adhesion Test

When an adhesion test is carried out, it shall comprised one of the following methods :

a. The Ring Test

A ring 75mm wide shall be cut cold from one end of finished pipes. The ring shall
be flattened at a temperature between 10
0
C and 21
0
C to 50% of the original
diameter. The lining and / or coating shall not part from the metal under this test.

b. The Strip Test


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Using a tool with a thin sharp blade, two cuts approximately 50mm apart shall be
made through the protection on the metal pipe. Sudden impact that would cause
ultimately separation shall be avoided. The blades shall be worked under the
protection and an attempt made to peel it from the metal. The adhesion shall be
considered satisfactory if removal of the protection causes cohesive failure and the
protection does not peel cleanly from the primer or the pipe surface.

c. Measuring Adhesion by Tape Test ASTM D 3359-93

Test method A is primarily intended for use at job sites. An X cut is made in the
film to the substrate, pressure sensitive tape is applied over the cut and then
removed, and adhesion is assessed qualitatively on the 0 to 5 scale. The acceptance
should be 4A-Trace peeling or removal along incision or at their intersection.

d. Pull-Off Strength of Coating Using Portable Adhesion Testers ASTM D 4541-93

This test method is for the determination of perpendicular force of the coating can
bear a plug of material is detached. It has to be carried on a flat surface. The general
pull-off test is performed by securing a loading fixture (dolly) normal (perpendicular)
to the surface of the coating with an adhesive. After the adhesive is cured, a testing
apparatus is attached to the loading fixture and aligned to apply tension normal
(perpendicular) to the test surface. The force applied to the loading fixture is then
gradually increased and monitored until either a plug of coating material is
detached or a specified value is reached. The acceptance criterion is a minimum
strength of 20 kg/cm
2
.

The tests shall be performed when the protection has been allowed to cure at a
temperature not less than 10
0
C or more than 35
0
C for a minimum of 48 hours after
application. However for pull-off adhesion test, a proper curing period of 7 days is
required before the test.

Note : When an adhesion test is required, this should be stated by the purchaser
during enquiring or ordering.









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STANDARD INSPECTION PROCEDURE (BLASTING)


A. BEFORE BLASTING


1. Condition of Rust
- Grade A, B, C, D
To check
2. Oil or grease solvent wipe in
accordance with SSPC-SP1

3. Sharp edges, wedge slag
- grind off


1. Grade / Mesh size
To check
2. Salt free and general utility



1. Test run for equipment

To check 2. Compressed air free from oil
and moisture trap and separator

INSPECTION OF
CASTINGS
INSPECTION OF
ABRASIVE
INSPECTION OF
BLASTING
EQUIPMENT
3. Pressure at blast hose nozzle
- hyperdermix needles (85
100psi)

4. No defective on blasting
nozzle








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B. DURING BLASTING




To check
1. Measure and record weather
condition dew point, relative
humidity, steel surface
temperature. No blasting shall be
allowed if steel temperature is not
at least 3
0
C above dew point

To check 1. Standards achieved visual
MEASURE AND
RECORD WEATHER
CONDITION
INSPECTION OF
CASTINGS comparison using Pictorial
Standard ISO 8504

2. Surface roughness of minimum
30 as measured by Keane-
Tator surface comparator

Note :

1. No blasting to be allowed if relative humidity is above 85% (Whitling Hygrometer
to be used). Casting surface temperature (using Magnetic Contact Thermometer) is
not more than 3
0
C above dew point (using Dew Point Calculator)

2. Blasted casting surfaces should be primed within 4 hours at normal weather
condition provided that no abrupt change in weather condition, and surface (rust
blooming).

3. Blasted surfaces left uncoated overnight shall receives a complete light blasting the
next day before priming.








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C. AFTER BLASTING


To check
No coating to be applied if casting
temperature is less than3
0
C above
dew point



To check
1. Sharp edges to be removed by
sanding down

2. Dust free surface to blow off
dust

Within 4 hours 3. Dust/pollution free environment
to be applied when blasting
work is being carried out nearby
CHECK WEATHER
CONDITION
INSPECTION OF
CASTINGS
PAINT APPLICATION












SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORKS

First Edition: May 2007

References of Cold-Applied High Solids (solvent or solventless) Epoxy
as Internal and External Coating System For Metal Surfaces Suitable For Portable Water
(Using High Solids (solvent or solventless) Epoxy-Based Primer/Topcoat)

Jotun

Dimet Courtaulds Coatings
(International Paint)

Nippon Paint Manufacture Description

Jotamastic 87


Naviguard

Amerlock 400

Amercoat 395
Intergard Potable
Water Tank
Coating
Interline 925 Coppon EA-9
Finish HB

Certification
AWWA C210 84
by COT
10 Dec 92
AWWA C210
84/92 by COT
27 Sep 94

Coating System

1 or 2 coats 1 or 2 coats 1 or 2 coats 2 coats Multicoat System Multicoat System 2 coats
Colour

Varieties Varieties Varieties White. Off-
White Orange
White, Pink Cream, White Varieties
Solids Volume 82% 2% 100% 83% 3% 91% 3% 56% 100% 55%
DFT per Coat 150 - 400 150 - 400 100 - 210 75 - 125 125 300 - 600 150
Recommended Total DFT 400 400 400 400 400 400 400

Application Method
Airless or
Conventional
Spray
Airless or
Conventional
Spray
Airless or
Conventional
Spray
Airless or
Conventional
Spray

Airless Spray

Airless Spray
Airless or
Conventional
Spray

Drying Period


Touch Dry
Hard Dry
Curing


BS 3900 C2 & C3
(35
0
C)

2.5 hrs
5 hrs
3 days

BS 3900 C2 & C3
(35
0
C)

2.5 hrs
4 hrs
3 days

ASTM D1640
(32
0
C)

4.5 hrs
12 hrs
4 days

ASTM 1640
(21
0
C)

6 hrs
24 hrs
7 days


(35
0
C)

1 hrs
3 hrs
-


(35
0
C)

4 hrs
8 hrs
-



(25
0
C - 35
0
C)
2 hrs
16 hrs
9 days
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Appendix 6
Polymeric Coating


1. Materials and Thickness

Pipes and fittings shall be coated with either a thermoset or thermoplastic polymeric
coating material. The coating shall be applied using either the fluidized bed dipping
process or the electrostatic spray process. The minimum thickness of polymeric coating
material shall be not less than those specified below :

Coating Type Coating Thickness (m)

Thermoplastic 200 450

Thermoset 350 650

Note : A coating manufacturer may specify higher minimum coating thickness than those
specified above


2. Performance Testing

Water Quality

All coating material in contact with or likely to come in contact with potable water
shall meet the requirements of BS 6920 Part 1.


3. Physical Characteristics and Performance

a. Holidays

Coating shall be tested in accordance with AS 3894.2. Only pinhole-free coated test
piece shall be used in subsequent performance test.

b. Hot Water Immersion

Test in accordance with AS 3862 at 60
0
C 21C for 100 days. The coating shall have
a rating of equal to or greater than four when tested in accordance with method
408.2 of AS 1580, immediately after exposure.

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c. Water Absorption

d. Flexibility

When tested in accordance with AS 3682 at 0
0
C, the coating shall not crack when
strained at 1.0% as calculated in the following equation :


Strain = 100 Sc %
2R Sc

where Sc Sample Thickness
R Radius of Mandrel

e. Impact Resistant

When tested in accordance with ASTM G14 at 23
0
C, the impact resistant shall be
equal to or greater than 2.0 J. The test may either be conducted on pipe with an
outside diameter of 110mm to 125mm and wall thickness from 5mm to 7mm (6mm
for flat plate). If cast plate is used, the side in contact with the anvil shall be
machined flat prior to testing.

f. Abrasion Resistance

The abrasion resistance test shall be undertaken according to ASTM D4060 with
CS18 wheel, 1000 cycles at 23
0
C 21C. The weight loss shall be equal to or less
than 40mg.

g. Cathodic Disbondment

Coated test piece shall be tested according to sections 5, 6, 7, 8 and 9 of BS 3900 :
F 11. The coating when subjected to an impressed current at a negative voltage of
1.5V, shall not disbond more than 5mm radially from the end of the damaged
coating after 28 days.

h. Cure Test

This test applied only to thermosetting coatings, including liquid thermosets. After
an appropriate combination of time and conditions (both to be defined prior to the
test by the manufacturer) from the point of coating application, thermosetting
coating on coated test pieces shall be demonstrated to have been cured within

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clared limits. The method used shall also be declared. Whenever practicable, the
method chosen should produce quantitative results.

Thermoplastic coating do not required this test.

i. Adhesion Test

Adhesion testing shall be carried out to determine the adhesive strength of the
coating to the substrate. It does not prove cohesive strength of the coating. Testing
shall be by means of a V-cut test. Toughness of the film and visual evidence of
coating in the anchor pattern valleys will give good indication of satisfactory
adhesion.

The test shall be carried out using a sharp knife. Two cuts are made in the coating at
an included angle of approximately 30
0
. Using the sharp point craft knife or similar,
the knife shall be used to attempt to lift the point of V in a single action levering
against a fulcrum. Not more than 2mm of the V shall be removed by this method
by adhesive failure to the substrate or the adhesion shall be considered to be
unsatisfactory.

The purchaser shall state his requirement for an adhesion test and the frequency of
testing at the time of enquiry and order.



j. Salt Spray Test

Prior to exposure, each test piece shall have a V cut made through the coating in
accordance with D.3.10. Coated test pieces shall undergo 2100 hours exposure to
salt spray in accordance with BS 3900 : F4. After exposure, the underfilm corrosion
must not extend more than 1mm from the cut edge of the coating. There shall be no
blistering in this area.

Addition, a V cut test shall be carried out in accordance with D.3.10 on the
undamaged side of the sample after exposure. On this side, there shall be not more
than 1mm disbondment, no underfilm corrosion and no blistering.
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