MASTER SPECIFICATIONS INFRA-GROUP

SPECIFICATION FOR HIGH DENSITY

POLYETHYLENE (HDPE) PIPES,
FITTINGS AND ACCESSORIES

CLIENT : AMER GROUP

PROJECT : PORTO OCTOBER
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 MASTER SPECIFICATIONS INFRA-GROUP

Table of Contents page

1. SCOPE...................................................................................................3
2. APPLICABLE STANDARDS AND CODES ..........................................3
3. TECHNICAL REQUIREMENTS.............................................................4
3.1 Material........................................................................................4
3.2 Pipe Dimensions..........................................................................5
3.3 Pipe Appearance.........................................................................5
3.4 Fittings.........................................................................................5
4. INSPECTION AND TESTING................................................................6
4.1 Certification and Documentation..................................................6
4.2 Test Results and Frequencies.....................................................6
4.3 Inspection and Audit Requirements.............................................6
4.4 Acceptance Criteria .....................................................................7
4.5 Defects ........................................................................................7
5. QUALITY ASSURANCE/QUALITY CONTROL.....................................7
6. PACKING, MARKING AND VENDOR DOCUMENTATION..................8
6.1 Pipe Identification ........................................................................8
6.2 Shipping ......................................................................................8
6.3 Trucking.....................................................................................10
6.4 Silo's ..........................................................................................10
6.5 Banding .....................................................................................10
6.6 End Caps...................................................................................10
6.7 Vendor Documentation..............................................................10

CLIENT : AMER GROUP

PROJECT : PORTO OCTOBER
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 MASTER SPECIFICATIONS INFRA-GROUP

1. SCOPE
This Material Specification details the minimum requirements for the design,
manufacture, testing, inspection and supply of High Density Polyethylene
(HDPE) or High Performance Polyethylene (HPPE) pipe material and fittings
to be used for transport and distribution of
potable water.

2. APPLICABLE STANDARDS AND CODES

The following codes and standards, to the extent specified herein, form a part
of this specification. The latest edition of these codes and standards shall
govern the work.
ISO 4427 Polyethylene (PE) pipes for water supply – specifications ISO 161-1
Thermoplastic pipes for conveyance of fluids – nominal outside diameter and
nominal pressure- part 1: Metric series
ISO 1167 Thermoplastic pipes for the conveyance of fluids – Resistance to
internal pressure – Test Method
ISO 3126 Plastic pipes – Measurement of dimensions
ISO 4065 Thermoplastic pipes – Universal wall thickness table
ISO 6964 Polyolefin pipes and fittings – Determination of carbon black content
by calcination and pyrolysis – Test method and basic specification.
ISO 9080 Thermoplastic pipes for the transport of fluids – Method of
extrapolation of hydrostatic stress rupture data to determine the long-term
hydrostatic strength of thermoplastic pipe materials.
ISO 11922-1 Thermoplastic pipes for the conveyance of fluids – Dimensions
and tolerances Part: 1: Metric series.
ISO 12162 Thermoplastic materials for pipes and fittings for pressure
applications – Classification and designation – overall service (design)
coefficient.
ISO 13761 Plastic pipes and fittings – pressure reduction factors for
polyethylene pipeline systems for use at temperatures above 200 C.
ISO 7005 – 3 Metallic flanges – Part 3, Copper alloy and composite flanges
PR EN 12201 Plastic piping systems for water supply – polyethylene

3. TECHNICAL REQUIREMENTS
3.1 Material
3.1.1 Material Requirements
The CONTRACTOR shall identify the manufacturer of the resin, the resin type
and classification. In addition, the CONTRACTOR shall provide evidence that
the resin proposed is suitable for use at the design temperature and under the
design pressures indicated.
Any change in the material, the material specification, or the manufacturer's
location shall be subject to prior approval of the ADWEA/ENGINEER.

CLIENT : AMER GROUP

PROJECT : PORTO OCTOBER
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 MASTER SPECIFICATIONS INFRA-GROUP

Pipes and fittings shall be homogenous throughout and free from visible
cracks, holes, foreign inclusions, blisters, dents or other damaging defects.
Joints are not acceptable.
Material shall be uniform in opacity, density, interior smoothness, and other
physical properties. It shall have adequate resistance to weathering and other
ageing from outside storage for a minimum of two years after manufacture.
The material of the polyethylene pipes and fittings which is in contact with or
likely to come in contact with drinking water shall not constitute a toxic hazard,
shall not support microbial growth and shall not give rise to unpleasant taste
or odour, cloudiness or discoloration of the water.
The concentration of substances, chemical and biological agents leached
from materials in contact with drinking water, and measurement of the
relevant organoletpic / physical parameters, shall not exceed the maximum
values recommended by the World Health Organisation in its "Guidelines for
Drinking Water Quality" or the EEC Council Directive on the "Quality of Water
Intended for Human Consumption", whichever is more stringent in each case.
If rework material is added or used, it shall be clean, derived from the same
resin and reground under the supervision of the same manufacturer and shall
be compatible with the material to which it is added.
The pipes and fittings shall be manufactured from polyethylene containing
only those antioxidants, UV stabilisers and pigments necessary for the
manufacturing of the pipes and confirming to the requirements of ADWEA /
ENGINEER and the specification.
All pipes and fittings shall be suitable for butt fusion or electro fusion welding
techniques.

3.1.2 Physical Properties

Polyethylene pipes and fittings shall be high density polyethylene pipes
(HDPE) and shall comply with the requirements of ISO 4427 type PE 100.
The minimum required strength (MRS) of the material compound shall be 10
MPa at 200 C and 50 years life time. The design stress shall be 8 MPa.
The polyethylene pipes and fittings shall meet the following specification:
- Minimum density measured according to ISO 1872 > 959 Kg/m3.
- Melt flow rate measured according to ISO 1133 - at 2.16 kg load < 0.15 g /
10 min.
- at 5.0 kg load < 0.5 g / 10 min.
- Tensile strength at yield = 23 MPa.
- Elongation at break at > 600%.
- Thermal conductivity at = 0.4 W/m0 K.
- Vicat softening point at 1 kg load = 1240 C.
The thermal stability of polyethylene material shall meet the requirements of
ISO 4427.

CLIENT : AMER GROUP

PROJECT : PORTO OCTOBER
03030 - 4
 MASTER SPECIFICATIONS INFRA-GROUP

3.2 Pipe Dimensions

The pipe dimensions, which are based on standard dimensions ratio 11 (SDR
11) are specified in Table 1.
Table 1 : Pipe dimensions.

Nominal Outside Mean Outside Wall Thickness (mm)

Diameter (mm) Diameter
(mm)

Minimum Maximum Minimum Maximum

90 90.9 90.6 8.2 9.2
110 110.0 110.7 10.0 11.2

180 180.0 181.2 16.4 18.2

250 250.0 251.5 22.7 25.2

315 315.0 316.9 28.6 31.7

355 355.0 357.2 32.2 35.7
500 500.0 503.0 45.5 50.3
630 630.0 633.8 57.2 63.1

Straight pipe shall be supplied in standard lengths of 11.8 m (-0 + 150 mm)
measured at 230 C ± 20 C. Unless otherwise specified, coil lengths shall not
exceed 100 m.
The coils shall be wrapped and shall not be exposed to direct sunlight.

3.3 Pipe Appearance

All polyethylene pipes to be used for the transport and distribution of potable
water shall be black and have blue coloured markings.
The carbon black content in the compound shall be 2.25 + 0.25 % by mass
when measured in accordance with ISO 6964. The dispersion of carbon black
when determined in accordance with ISO 11420 shall be equal to or less than
grade 3.

3.4 Fittings
The fittings shall be injection moulded or formed from material compatible to
that of the pipe.

CLIENT : AMER GROUP

PROJECT : PORTO OCTOBER
03030 - 5
 MASTER SPECIFICATIONS INFRA-GROUP

At locations where HDPE to metal connections are specified, stub flanges

with Rilsan coated backing rings shall be used, or special restrained transition
fittings approved by the ADWEA/ENGINEER. The flanges shall be drilled to
ISO 7005-2, PN 10 or PN 16 as per the design requirements.

4. INSPECTION AND TESTING

4.1 Certification and Documentation
An authority appointed by the ADWEA shall certify all items supplied to this
Specification.
The MANUFACTURER shall document and certify all products and required
tests and CONTRACTOR shall supply the ADWEA/ENGINEER with copies of
these certifications and test documents. Such documentation shall be subject
to ADWEA/ENGINEER's approval prior to shipping.
All items shall comply with the requirements of ISO 4427 and any additional
requirements listed in this specification.

4.2 Test Results and Frequencies

The MANUFACTURER shall establish and maintain a current record of test
results according to the requirements of the applicable standards and this
specification.
The MANUFACTURER shall perform all the tests required by ISO 4427 to
demonstrate the characteristics and quality of the resin material and the
dimensional tolerances of the pipe.
The MANUFACTURER shall document all the tests, with frequencies and
results as indicated in ISO 4427.
Notes: For establishing test frequencies:
Coil and straight lengths are as noted in clause 3.2;
Straight length pipe shall be tested at the same frequency as coiled pipe;
A continuous production run is the manufacture of pipe of one resin type,
size, and wall thickness, for one purchase, with no interruption or change in
the manufacturing process.
The CONTRACTOR/MANUFACTURER shall supply the ADWEA/
ENGINEER, with copies of
all material certificates and inspection and test results obtained in the course
of quality verification. When requested, the MANUFACTURER shall also
provide access to and copies of all production record, process control charts,
and other records compiled during manufacture.

4.3 Inspection and Audit Requirements

Pipe shall comply fully with ISO 4427 and all the additional requirements of
this specification.
To verify compliance with this specification, the ADWEA/ENGINEER shall
appoint an independent third party inspector to witness the applicable
qualification tests, review production records, and inspect general handling
and shipping procedures.
The CONTRACTOR/MANUFACTURER shall give 7 days notice of its intent to
begin production to allow the ADWEA/ENGINEER to arrange for third party

CLIENT : AMER GROUP

PROJECT : PORTO OCTOBER
03030 - 6
 MASTER SPECIFICATIONS INFRA-GROUP

inspection. The third party inspector shall have full access to the testing and
production facilities and will be a fully authorized representative of the
ADWEA /ENGINEER.

4.4 Acceptance Criteria

The order shall meet the following criteria:
A copy of the raw material MANUFACTURER's "Certificate of Quality Control
Testing" covering each batch of raw material used for pipes purchased under
this specification, shall be available for inspection by the ADWEA/ENGINEER
on request.
Pipe wall thickness shall be controlled by continuous scanning using gamma
ray or other qualified devices. These devices shall be regularly calibrated for
accuracy.
Successful test performance and acceptable results for the testing program
outlined in this specification.
An acceptable inspection report from a third party inspection company (at the
option of the ADWEA/ENGINEER).
When performed, acceptable results from an independent test audit of any
portion of the tests noted in ISO 4427 and this specification.
The ADWEA/ENGINEER may reject any item that does not fully comply with
the requirements of this specification.

4.5 Defects
When the rejected item is a length or coil of pipe, the lengths or coils
manufactured immediately before and after the defective lengths or coils shall
be carefully examined.
If further defects are found, this is sufficient cause for rejecting the entire
batch. This will not apply to local damage that did not occur during
manufacture, such as gouges or cuts during handling or transit.

5. QUALITY ASSURANCE/QUALITY CONTROL

A copy of the MANUFACTURER's QA/QC program shall be submitted to
ADWEA/ENGINEER with its quotation for review and concurrence prior to
award.
If MANUFACTURER's facility is ISO certified, QA audit requirements will be
waived in favour of ISO 9000 registrar audits, unless the ADWEA /
ENGINEER's trend analysis program indicates areas of concern.

6. PACKING, MARKING AND VENDOR DOCUMENTATION

6.1 Pipe Identification
The marking information and sequence shall comply with ISO 4427 and this
specification.
All pipes and fittings, including test samples shall be clearly and permanently
marked using indent printing in a colour that contrasts with the pipe.
All marking shall be repeated at least every 1.0 m and shall be displayed on
the outside of the coil/length together with the following information:

CLIENT : AMER GROUP

PROJECT : PORTO OCTOBER
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 MASTER SPECIFICATIONS INFRA-GROUP

- MANUFACTURER's name or trademark

- resin name or type (to be proposed and subject to prior
ADWEA/ENGINEER's approval)
- the letters "PE" followed by the PE grade (e.g. PE100)
- the service, i.e. the word "Water" for water pipelines (blue marked)
- the nominal outside diameter (NOD) in millimetres (mm)
- standard dimension ration
- coil/length number
- plant location and date of manufacture, e.g. X 29 08 00, where X designates
the plant
- the letter "R" if regrind material was used
- production information, e.g. 251Y, where 2 indicates shift, 5 indicates
operator, 1 indicates extruder, and Y indicates compound supplier
The maximum quantity of pipe to have the same coil/length number is one
silo (coiled pipe) or one bundle (straight lengths). The maximum combined
length of pipe in the silo or bundle with the same coil/length number shall not
exceed the maximum allowable coil length specified in clause 3.2.
When pipe material is boxed, the coil number shall be clearly marked on the
outside edge of the box or silo. Invoices and packing lists shall include the
date of manufacture and coil/length numbers for all material in the shipment.

6.2 Shipping
The CONTRACTOR/SUPPLIER shall provide packing and shipping
procedures for approval by the ENGINEER and shall comply with the
following requirements.

6.2.1 Delivery
Delivery of the plastic pipes and fittings to site, shall be no later than six
months after the stamped manufacture date, for it to be acceptable.
Pipes boxed immediately after extrusion and stored indoors, as well as pipes
protected from UV light immediately after manufacture as per the
requirements of clause 6.2.2, are - at the ENGINEER's discretion - exempt
from this requirement and are acceptable up to one year after manufacture.
6.2.2 UV Protection
To obtain this exemption (from clause 6.2.1), the CONTRACTOR/
MANUFACTURER shall inform the ADWEA/ENGINEER one month prior to
manufacture for inspection and approval of the protective method. All silos of
coiled pipe shall be shrink-wrapped in UV-blocking black plastic.
The black plastic shall be thick enough to prevent accidental tearing and
passage of visible light.
The UV-blocking plastic wrap shall filter out 100% of the UV radiation from
reaching any portion of the PE pipe.
IF the plastic is not black, the MANUFACTURER shall receive prior approval
from the ENGINEER before the wrap is used. Approval of non-black shrink
wrap plastic may involve testing. The cost of this testing shall be to the
account of the CONTRACTOR/MANUFACTURER.

CLIENT : AMER GROUP

PROJECT : PORTO OCTOBER
03030 - 8
 MASTER SPECIFICATIONS INFRA-GROUP

6.2.3 Tie-Downs
Tie-downs shall be at least 100 mm wide and be clean and free from sand,
gravel and other such materials. For straight length pipe (up to 12 m), a
minimum of 6 tie-downs are required.

6.2.4 Pallets
The pallets shall be suitable for transporting the material from the place of
manufacture to the designated receiving location without causing any damage
to the pipe.
The pallets shall not contain any broken planks or extremities that may
damage the coiled pipe or straight lengths.
They shall be durable enough to prevent loose pallet nails from gouging the
bottom coil/straight length. Pallet construction shall be subject to approval by
the ENGINEER.

6.2.5 Overhang
Pipe shall not overhang at either end of the trailer.

6.2.6 Stacking
The CONTRACTOR/MANUFACTURER shall not ship small coils stacked
inside silos of larger coils.
Frames manufactured for the containment of straight lengths of polyethylene
pipe during transport and storage shall not contain nails or other fastening
devices that may damage the pipe.

6.3 Trucking
Where pipes are transported by vehicles, the vehicles should have a flat bed
and be free from sharp edges or projections.
During transport, polyethylene pipes shall be protected from diesel fumes and
be continuously supported to prevent movement between the material and
its support.

6.4 Silo's
Silo packs of coiled pipes shall be squarely stacked and well supported on
pallets.
Coils shall not overhang the pallets and, unless approved by the ADWEA /
ENGINEER, shall not be stacked higher than 2.3 m.

6.5 Banding
All coils shall be banded at intermediate stages of coiling and upon
completion of the specified length. Al least 8 intermediate bands shall be
provided on 150 m coils.

6.6 End Caps

Straight lengths and coils of pipe shall have internally fitted end caps that
prevent dirt and debris from entering the pipe during handling, storage and
transport.

CLIENT : AMER GROUP

PROJECT : PORTO OCTOBER
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 MASTER SPECIFICATIONS INFRA-GROUP

Caps shall be attached by an approved method to prevent the accidental loss

of the cap. All end caps shall have an outer lip, which prevents the accidental
insertion of the cap into the pipe.
A method to permit venting shall be provided in order to allow expansion of
air due to temperature changes during storage.

6.7 Vendor Documentation

The CONTRACTOR shall furnish following vendor data as a minimum, with
the bid:
- Catalogues/Brochures.
- Dimensional details of pipes and fittings.
- Detailed material specifications.
- Manufacturer's drawings.
- Complete details of testing facilities available at manufacturer's works.
- Local (UAE) agent name and address.
Bids not accompanied by any of above mentioned information/data shall be
.considered incomplete, and liable to be rejected

CLIENT : AMER GROUP

PROJECT : PORTO OCTOBER
03030 - 10