Professional Documents
Culture Documents
Technical Specifications
Volume 3
Water Distribution & Collection
Networks
2
1
0
Revision
Tender Issue
100% CD 2nd Stage Tender Issue
85% Submission For Review
Purpose Description
SA
SA
SA
Originated
ML
RP
DS
Checked
ML
HS
HS
Authorised
18/10/07
08/10/07
19/12/06
Date
BAHRAIN BAY
Technical Specifications - Volume 3
Water Distribution and Collection Networks
Contents
Section
Page
GENERAL REQUIREMENTS
1.1
SCOPE OF WORK
1.1.1
1.1.2
1.1.3
1.1.4
Irrigation
Potable Water and Fire Fighting
Foul Water
Storm
5
5
5
6
1.2
GENERAL REQUIREMENTS
1.3
LAYOUT OF WORK
1.4
CLEAN-UP
1.5
WARRANTY
1.6
SUBMITTALS
2.1
2.2
NO OBJECTION CERTIFICATES
2.3
2.4
MANUFACTURERS CERTIFICATIONS
2.4.1
2.4.2
9
9
2.5
2.6
SPARE PARTS
10
2.7
10
2.8
MANUFACTURER'S LITERATURE
10
2.9
AS-BUILT DRAWINGS
10
12
3.1
DEFINITION
12
3.2
12
3.3
12
14
4.1
GENERAL REQUIREMENTS
14
4.1.1
4.1.2
4.1.3
Standards Specifications
Scope of Work
Standards
14
14
14
4.2
15
4.3
EXECUTION
15
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
Pipe Materials
Pipe Installation
Jointing
Excavation and Backfilling
Underground Warning Tape
15
16
16
17
17
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4.4
17
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
17
18
19
20
20
20
4.5
PAINTING
21
4.6
22
4.7
CLEANING
22
4.8
DISINFECTION
22
23
5.1
GENERAL
23
5.1.1
References
23
5.2
PIPE MARKING
23
5.3
23
5.4
QUALITY ASSURANCE
24
5.5
24
5.6
26
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.6.6
Testing
Design Parameters to be Considered by the Contractor
Additional requirements: GRP Pipe Data to be Submitted.
Handling and Installation Specification
Tests for GRP Pipes
Required Pipe Data
27
27
28
29
29
33
5.7
33
PIPE LAYING
34
6.1
GENERAL
34
6.2
PIPE BEDDING
35
6.3
35
6.4
36
6.5
BACKFILLING
36
6.6
36
6.6.1
6.6.2
6.6.3
Gullies
Pre-formed Gullies
Manhole
36
37
37
6.7
38
6.7.1
General Requirements
38
6.8
THRUST BLOCKS
39
6.9
VALVES
39
6.9.1
6.9.2
6.9.3
6.9.4
6.9.5
General
Check Valves
Gate Valves
Air Valves
Penstocks
39
40
41
41
42
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6.9.6
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GENERAL REQUIREMENTS
1.1
SCOPE OF WORK
The work consists of the provision of new services and comprises the installation, testing and
commissioning of the following services networks as summarised below, and as per this
Specification and Contract Drawings.
1.1.1
Irrigation
The system comprises of an irrigation water supply network to meet the irrigation
requirements of the Bahrain Bay for a 24-hour period of irrigation demand. The irrigation
network will be pumped from an irrigation reservoir (by others) located adjacent to the
Sewage Treatment Plant offsite.
The reticulated irrigation supply network covers the Bahrain Bay site and is fed by a single
connection across the North Manama Causeway (NMC) as per the Contract Drawings.
The Scope of Work includes the primary irrigation network, service connections, NMC
crossing terminating adjacent to the offsite STP at the interface point identified on the
Drawings.
The work consists of pipelines with diameters ranging from 150 mm to 300 mm.
1.1.2
1.1.3
Foul Water
The proposed foul water system for the Bahrain Bay development is generally a gravity
sewerage system. The infrastructure works shall comprise the construction of the gravity
network sewers with future stub ends located at the parcel boundaries of each development
package. The sewerage network is designed to keep the network above the ground water
table to avoid infiltration into the network.
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Both North and South Island will have independent foul gravity sewers and Foul Pumping
Stations each from where the foul sewer will be pumped through force mains to the Sewerage
Treatment Plant (by others) located offsite.
1.1.4
Storm
The Proposed Storm Water System for the Bahrain Bay development is a gravity drainage
system. The infrastructure works shall comprise of the construction of gravity network drains,
future stub ends located at parcel boundaries, road gullies, gully connections to the main
network and oil interceptors. The Storm Water Drainage outfalls through the Quay walls have
already been installed under the Marine Construction Package. These outfalls have been left
with a pipe protruding out of Quay Walls stone backing for the Infrastructure Contractor to
connect to.
The Storm Drainage Network is designed to keep the network above the groundwater table to
allow the system to be a gravity drainage system. Each of the drainage runs are independent
of the others and will transport the storm water to an oil interceptor before it is released into
the sea.
1.2
GENERAL REQUIREMENTS
Services shall be installed in a sequenced and logical manner to minimise the requirement to
protect any previously installed services.
The Contractor shall include for all materials, labour, plant and tools.
Where new cable/ducts/pipes are to be laid along side, over or under the Contractors
previously installed services, the Contractor shall take care to interfere as little as possible
with the existing services and connections thereto and any damage shall be repaired by the
Contractor to the satisfaction of the Engineer. Any previously installed services shall be
protected before commencing earth works in their vicinity.
All concrete works shall conform to the requirements of the Technical Specifications Volume
13 Concrete.
The Contractor shall be responsible for public safety during execution of work. He will take all
steps, including where necessary the provision of ropes, picket fence, etc. on each side of the
trenches and excavations with warning lights and night watchman, etc. to ensure the safety of
the public. The Contractor will be held responsible for any damage to property or injury to
persons due to his negligence. Any instruction from the Engineer concerning the safety
aspects of the work must be carried out immediately, but the Contractor shall remain
responsible for the adequacy of the safety measures.
1.3
LAYOUT OF WORK
The Contractor shall stake out the water systems in accordance with the design drawings.
Staking shall be erected in such a manner as to ensure permanency of the staked locations
until such time as the respective system is installed. Stakes shall be placed to show location
of valves, pipelines and control head. Stakes shall be flagged with bright flagging for ease of
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location. All staking by the Contractor shall be subject to agreement of the Engineer. Any
stakes disturbed by other works shall be reinstated by the Contractor as early as practicable
in the circumstances.
1.4
CLEAN-UP
During the course of construction, the Contractor shall remove waste material from the site
continually as is necessary to keep the site in an orderly manner. Waste material shall be
removed from the work site and not to be used as back-fill material. Upon completion of the
Contract, the Contractor shall remove all waste equipment and parts and leave the site in a
neat and orderly condition.
1.5
WARRANTY
All work included under this Contract shall be warranted by the Contractor against all defects
and malfunction of materials and workmanship for a period of one year from the date of
completion of works. Should problems arise with the system during the warranty period, all
necessary repairs and/or replacements shall be made by the Contractor in an expedient
manner at no additional cost to the Employer.
1.6
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SUBMITTALS
The Contractor shall order materials to suit the construction programme and shall plan
his necessary submittals to the Engineer in accordance with the Technical Specifications
Volume 1 General in a timely manner to suit the ordering, delivery and construction timing
requirements. The Contractor shall submit as a minimum the following documents for review
by the Engineer:
2.1
information:
-
Originals of catalogues and engineering data sheets for manufactured items; each item
and option to be provided shall be clearly marked and each item not to be provided
shall be deleted.
Literature to show that products provided meet the requirements for material,
construction, operation, and testing.
Information on the following items as a minimum: pipes; pipe jointing systems, manhole
covers and frames and gully covers, gratings and frames.
Certified reports for all tests and inspections designated herein, signed and sealed,
showing full compliance with referenced standards.
2.2
NO OBJECTION CERTIFICATES
Prior to start of any work on government property the Contractor has to approach all relevant
Service Authorities in Bahrain to get their no objection for the work included in this contract
and a record drawings for their existing services. Copy of these drawings and no objection
certificate should be submitted to the Engineer before starting the actual work at site. In
addition, for work on Bahrain Bay development land the Contractor shall make all necessary
submissions to the Ministry of Water and Electricity, EDD to obtain their no objection
certificate ensuring that the works covered by this Specification will not invalidate the
adoptability of the High and Low Voltage networks within Bahrain Bay.
All the works executed in Bahrain Bay should be in compliance with the requirements of MEW
and MoWH of Bahrain unless specified otherwise in the Technical Specifications and
Drawings.
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2.3
Profiles of each pipe system including chainage, ground levels, invert levels, critical
clearances and position of pipework structures.
Material, class, grade, joint type, pressure rating, dimension, location and identification
number of each pipe and pipe fitting to be furnished and installed.
Class, dimensions, location and identification of each manhole cover and frame to be
furnished and installed.
Class, dimensions, location and identification of each gully cover, grating and frame to
be furnished and installed.
Procedures for placing and fixing gully covers, gratings and frames.
Details for handling and storage of pipes, manhole covers and frames and gully covers,
gratings and frames.
The review of Shop Drawings by the Engineer shall not relieve the Contractor of any of his
responsibility under the contract for successful completion of the work.
2.4
MANUFACTURERS CERTIFICATIONS
2.4.1
2.4.2
2.5
Contractor
shall
submit
manufacturers'
recommendations
for
installation
and
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available on site at all times while work is in progress and shall follow these instructions
unless otherwise authorized to deviate by the Engineer.
2.6
SPARE PARTS
The Contractor shall submit manufacturer's list of spare parts prior to commissioning any
piece of equipment. Recommendations shall include stocking recommendations, exploded
assembly diagrams illustrating location and spare parts to be utilised and all relevant
operational data.
2.7
2.8
MANUFACTURER'S LITERATURE
At such time as the list of materials has been accepted by the Engineer, the Contractor shall
provide six (6) sets of manufacturer's technical & maintenance literature including M&E
specifications to the Engineer including an electronic copy in PDF format. Data sheets shall
provide sufficient technical information to identify each product and shall include the name
and the address of the nearest supply firm, which should have a local representative in
Bahrain.
2.9
AS-BUILT DRAWINGS
The Contractor shall maintain one set of contract drawings for the sole purpose of recording
accurate changes made as the work progresses ("As-Built" conditions) of the water systems.
All changes previously agreed with the Engineer and all completed work shall be recorded on
these drawings.
The Contractor shall prepare as-built drawings clearly showing all location, depths, slopes,
heights, shapes and dimensions of all works as executed. All valve locations and piping shall
be dimensioned and recorded. The Contractor shall submit as-built drawings for all electrical
installations.
Sizes of all the as-built drawings should be in accordance with MEW-WDD and MoWH-SDD
Standards.
Contractor shall prepare and submit as-built drawings for the pipeline profiles. Pipeline profile
drawings shall be in Horizontal scale of 1:1000 and Vertical scale of 1:100. Pipeline profiles
shall be submitted on separate drawings with clear references to layout drawings marked on
the same.
Chambers Schedule shall be prepared indicating all relevant construction items and giving coordinates for each manhole in compliance with Bahrain grid System.
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The Contractor shall submit as-built drawings for all the electro-mechanical installations. All
details of the installed equipment regarding Manufacturer, and Model No., Type, size, etc.,
shall be provided in the legend of the drawings.
After final acceptance of the As-Built Drawings, the Contractor shall submit the required sets,
as specified in the Technical Specifications Volume 1 General.
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3.1
DEFINITION
Products mean new material, machinery, components, equipment, fixtures, and systems
forming the Work.
3.2
3.3
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Fabricated products stored externally shall be placed on pallets or other means of above
ground storage.
The Contractor shall provide off-site storage and protection when the site does not permit
on-site storage or protection.
The Contractor shall cover products subject to deterioration with impervious sheet covering
and provide ventilation to avoid condensation.
The Contractor shall provide equipment and personnel to store products by methods to
prevent soiling, disfigurement, or damage.
The Contractor shall arrange storage of products to permit access for inspection and shall
periodically inspect producte to assure that the products are undamaged and are maintained
under specified conditions.
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4.1
GENERAL REQUIREMENTS
4.1.1
Standards Specifications
This section deals with the specification for works to be carried out in connection with Water
Services pipe work.
All pipe material used for constructing the potable water distribution network and irrigation
water distribution network should be of HDPE fit for respective use and from a manufacturer
agreed with the Engineer.
General requirements for the potable water and irrigation water works shall conform to the
Ministry of Electricity and Water (MEW), Water Distribution Directorate and the Ministry of
Works and Housing (MoWH), Sewerage and Drainage Directorate specifications respectively
and the specific requirements of this Technical Specification.
Foul water network pipe material for diameters up to and including 300mm should be of uPVC
capable of handling foul sewer, fit for respective use and from a manufacturer agreed with the
Engineer. Foul water network with pipe diameter above 300mm should be of GRP capable of
handling foul sewer water, fit for respective use and from a manufacturer agreed with the
Engineer.
Storm Water Network pipe material for diameters up to and including 400mm should be uPVC
capable of handling storm water, fit for respective use and from a manufacturer agreed with
the Engineer. Storm water network with pipe diameters above 400mm should be of GRP
capable of handling storm water, fit for respective use and from a manufacturer agreed with
the Engineer.
General requirements for the foul and storm water works shall conform with the MoWH SDD,
Standard Specification for Sewerage and Drainage Civil Engineering Works and the specific
requirements of this Technical Specification.
4.1.2
Scope of Work
The works include for the supply, installation, testing and commissioning of the Water
Services installation, the layouts for which are shown on the Drawings. Future connection for
the secondary and tertiary irrigation system will be undertaken using saddle connections and
shall be the responsibility of the tertiary irrigation system designer. However, the Scope of
Works does include service connections that are detailed in the Drawings.
The Contractor shall include for all labour, materials, tools and tackle, complete with all
trenching and backfill.
The Contractor shall include for the preparation for all necessary working Drawings. The
Contractor shall be responsible for the correct setting out of the installation.
4.1.3
Standards
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All calculations, drawings and submissions shall be in SI (System International) units. Material
items shall be to the latest BS (British Standard) or equivalent comparable internationally
recognised standard of construction and quality.
4.2
4.3
EXECUTION
4.3.1
Pipe Materials
Rider Sewer
Storm Water
Irrigation Main
Potable Water
RI4326-D905-R3-0021
Location
Material
Land
Land
Land
Land
Bridge
Land
Land
Land
Land
Bridge
uPVC
GRP
GRP
GRP
DI
uPVC
uPVC
GRP
HDPE
Epoxy lined DI
All
All
Land
Bridge
HDPE
Cement lined DI
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4.3.2
Pipe Installation
Pipe installation shall be in accordance with the general pipe laying requirements of the WDD
and SDD Standard Specifications and the specific requirements as follows:
-
Necessary facilities including slings shall be provided for lowering and properly placing
the pipe section in the trench without damage. The pipe sections shall be laid to the line
and grade shown and they shall be closely jointed to form a smooth flow line.
Immediately before placing each section of pipe in final position for jointing, the bedding
for the pipe shall be checked for firmness and uniformity of surface.
At all times when the work of installing pipe is not in progress, all openings into the pipe
and the ends of the pipe in trenches or structures shall be kept tightly closed to prevent
entrance of animals and foreign materials. The Contractor shall take all necessary
precautions to prevent the pipe from floating due to water entering the trench from any
source, shall assume full responsibility for any damage due to this or any other cause,
and shall at his own expense restore and replace the pipe to its specified condition and
grade if it is displaced. The Contractor shall maintain the inside of the pipe free from
foreign materials and in a clean and sanitary condition until handover.
All piping and fittings shall be installed true to alignment and rigidly supported.
Anchorage shall be provided where required. Any damage to linings shall be repaired
to the satisfaction of the Engineer before the pipe is installed. Each length of pipe shall
be cleaned out before installation. All of manufacturer's recommendations shall be
complied with.
The deflection at joints shall not exceed that recommended by the pipe manufacturer.
Fittings, in addition to those shown on the Drawings, shall be provided, if required, in
areas where conflict exists with the existing facilities.
When pipe cutting is acceptable to the Engineer, the cutting shall be done by abrasive
saw, leaving a smooth cut at right angles to the axis of the pipe. Any damage to the
lining shall be repaired to the satisfaction of the Engineer.
4.3.3
Jointing
Jointing shall conform to WDD and SDD Standard Specifications and the following specific
requirements.
-
Flanged joints shall be made using gaskets, bolts, bolt studs with a nut on each end, or
studs with nuts where the flange is tapped. The number and size of bolts shall conform
to the same ANSI Standard as the flanges.
Bolts in flanged joints or mechanical joints shall be tightened alternately and evenly.
Sleeve type couplings and grooved joints using split ring couplings shall be installed in
accordance with the procedures recommended by their respective manufacturers.
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manufacturers have indicated requirements that piping loads shall not be transmitted to
their equipment, submit a certification stating that such requirements have been
complied with.
4.3.4
4.3.5
Colour
Red
Red
Orange
Grey
Blue
Caution
Caution: Sewage Pipe Below
Caution: Sewage Pressure Main Below
Caution: Irrigation Pipe Below. Not for Drinking.
Caution: Storm Drain Below
Caution: Water Main Below. (Potable water mains
shall be protected in accordance with the requirements
of the MEW, Water Distribution Directorate,
Specifications of Items for Water Supply
All warning tapes shall be submitted to the Engineer for acceptance prior to delivery to site.
Warning tape shall be high quality, acid and alkali-resistant polyethylene film 300 mm wide,
and with a minimum thickness of 0.10mm. The tape shall be laid in a continuous manner
above each service at depth of 0.3m below ground level, and shall be continuously and
indelibly marked in English and Arabic with the appropriate wording.
Tape shall be printed with 50 mm high black lettering or white lettering where the tape is
black. The complete wordings shall be repeated every 2m along the tape. The colours shall
be vivid, glossy and permanent with a life expectancy of 40 years.
Warning tapes shall be placed with the inscriptions facing upwards. The level of the tape
relating to the top of service shall be in accordance with the requirements of the relevant
services standard detail Drawings.
Warning tapes over non-metallic services shall be backed with Aluminium foil to facilitate
detection.
4.4
4.4.1
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-
Except as otherwise indicated, the current editions of the following Standards apply to
the work in this section;
a.
ASTM D 2447-95
ASTM F 714-95
Polyethylene pipes with outside diameter less than or equal to 12 (406 mm) shall be
manufactured under ASTM D 2447-95 -Standard Specification for Polyethylene (PE)
Plastic Pipe, Schedules 40 and 80, based on Outside Diameter while polyethylene
pipes with outside diameter greater than 12 (406 mm) shall be manufactured under
ASTM F 714-95 -Standard Specification for Polyethylene (PE) Plastic Pipe, (SDR-PR)
based on Outside Diameter.
All compound used shall be virgin plastic. Clean work material from the manufacturers
own pipe production maybe used so long as the original was virgin material and of the
same type, class and grade as required above.
When used under conditions for which they are designed, pipe materials shall not
constitute toxic hazard, shall not support microbial growth and shall not give rise to
unpleasant taste or odour, cloudiness and discoloration of the water.
The pipe shall be homogeneous throughout and essentially uniform in colour, opacity,
density, and other properties. The inside and outside surfaces shall be semimatte or
glossy in appearance (depending on the type of plastic) and free of chalking, sticky, or
tacky material. The surfaces shall be free of excessive bloom, that is, slight bloom is
acceptable. The pipe walls shall be free of cracks, holes, blisters, voids, foreign
inclusion, or other defects that are visible to the naked eye and that may affect the wall
integrity.
4.4.2
Jointing
The jointing system for HDPE pipes and fittings shall be in accordance with the butt-fusion
method and the pipe manufacturers recommendations subject to acceptance by the
Engineer. When the pipes supplied under these Specifications are installed and joined by this
method, the work shall be carried out only by well-qualified personnel who adhere strictly to
prescribed working conditions, using tools and procedures recommended by the manufacturer
and accepted by the Engineer.
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-
General Procedure - The following procedure shall be followed when making a buttfusion joint unless agreed otherwise with the Engineer:
a.
Wipe each pipe-end clean, inside and out to remove dirt, water, grease, and
other foreign material.
b.
Square off the end of each pipe section to be used using a facing tool. Remove
cuttings and burrs from pipe ends.
c.
Check line-up of pipe-ends in fusion machine to see that pipe ends meet
squarely and completely over the entire surface to be fused. Two clamps should
be used on each end of pipe to be fused for sizes 100 mm and above.
d.
Insert the heater plate between the aligned pipe ends. Bring and hold the pipe
ends in contact with the heater plate. Maintain contact and allow pipe to heat and
soften until a bead of molten plastic rolls back from the ends. This bead will be
about 1.5 mm to 5.0 mm back from the end of the pipe depending on size. Soften
approximately 1.5 mm on all sizes up to 75 mm; on 75 mm to 150 mm heat to 3
mm and for the above 150 mm heat to 5 mm. Softening can be judged by the
appearance of the pipe end as the material softens.
e.
Both surfaces of the heater plate shall be clean and the temperature maintained
at 2460C-2600C (4750F to 5000F).
f.
Carefully move the pipe ends away from the heater plate and remove the plate.
If the softened material sticks to the heater plate, discontinue the joint. Clean
heater plate, re-square pipe ends and start over.
g.
Bring the heated pipe ends together with the specified pressure to form a uniform
double bead about 3 mm to 5 mm wide around the entire circumference of the
pipe.
h.
Allow the joint to cool and solidify while maintaining the pressure for the specified
time. Inspect the joint for a uniform non-porous appearance. If the joint appears
faulty, cut the joint out and repeat the procedure.
4.4.3
ASTM F 714-95 Standard Specification for Polyethylene (PE) Plastic Pipe, (SDR-PR)
based on Outside Diameter
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The pipes shall be tested in accordance with the methods prescribed in this standard. The
frequency of sampling and testing of pipes shall also follow the procedures stated in this
standard.
4.4.4
4.4.5
4.4.6
Thrust Restraints
-
General
a.
Ductile Iron pipe and fittings requiring thrust restraint shall be furnished with
push-on restrained joints or mechanical joint restraints as required.
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showing that restrained joints in the sizes specified have been successfully
tested to at least twice the specified pressure rating of the joint without leakage
or failure. Tests shall be performed on pipe with nominal metal thickness less
than or equal to that specified for the project. Torque-activated restrained joint
devices that rely on threaded bolts or set-screws for joint restraint shall not be
used.
d.
The mechanical joint restraining device shall have a working pressure rating of
200 psi minimum with a safety factor of at least 1.5:1 against separation when
tested in the dead-end situation.
4.5
PAINTING
Dry film thickness (DFT) of all painted valves and spool pieces shall be measured on delivery
to site. DFT shall be the average of no less than three measurements, with no one
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measurement less than 75% of nominal average DFT. Holiday tests shall be carried out on
internal and external surfaces on delivery, and also on external surfaces prior to back filling.
4.6
4.7
CLEANING
Clean the entire pipe by flushing with water or other means to remove all dirt, stones, pieces
of wood, or other material which may have entered during the construction period. All debris
shall be removed from the pipeline. The lowest segment outlet shall be flushed last to assure
debris removal.
4.8
DISINFECTION
Once completing distribution network and after performing all other necessary system
operating tests to obtain acceptance from the Engineer for taking over of the completed
system the Contractor should proceed to perform disinfection on the system through WDD
approved method and the system should be disinfected in the presence of the Employers
Representative and the Engineer for obtaining a taking over certificate.
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FOUL &
FITTINGS
5.1
GENERAL
STORM
DRAINAGE
PIPES
AND
This Part specifies the requirement for pipework, gullies, manholes, catch pits, and other
items related to drainage. Related Sections and Parts are as follows:
5.1.1
References
The following standards are referred to in this Part:
-
BS 497 Manhole covers, road gully grating and frames for drainage purposes
BS 4660 unplasticized polyvinyl chloride (PVC-U) pipes and plastic fittings of nominal
sizes 110 and 160 for below ground gravity drainage and sewerage
BS 6076 Tubular polythene film for use as protective sleeving for buried iron pipes and
fittings
BSEN 124 Gully tops and manhole tops for vehicular and pedestrian areas
BS 5480 Glass reinforced plastic (GRP) pipes and fittings for use for water supply or
sewerage
5.2
PIPE MARKING
Each pipe and pipe fitting shall be marked with the following:
5.3
Serial number
Class of pipe
Nominal diameter
Date of manufacture.
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Products susceptible to ultra violet degradation shall be stored under cover and out of direct
sunlight.
Pipes and fittings shall be subject to visual inspections after off-loading at the site and before
installation.
5.4
QUALITY ASSURANCE
Pipes, pipe fittings, manhole covers and frames and gully covers, gratings and frames shall
be supplied by manufacturers acceptable to the Engineer as designated in the Technical
Specifications. Production facilities shall be quality assessed in accordance with ISO 9000.
5.5
60 years
guarantee means that if the pipe is exposed and retested after 60 years of service then it
should retain at least 80% of its original properties.
With each consignment the supplier shall along with his delivery note, routine QC test reports
that shall also include the batch numbers that comprises the consignment, date of production
and numbers from each batch.
The traceability system of the supplies shall be such that it should be able to trace any failure
at least up to the raw material sources.
Any personnel from the Employer, his representatives or the Engineer wishing to visit the
supplier's yard, testing arena, storage area, etc. shall immediately be given access. If any
regular/random test, raw materials invoices or QA/AC records are requested to check the
continued compliance, such request shall be responded to immediately.
Pipes and fittings shall generally comply with DIN 8061/8062/8063 series unless particular
deviations and/or references are made. Irrespective of the application at the site all the PushFit-Rubber-gasketed jointed pipes shall be pressure rated into classes 6, 10 or 16 as
specified.
The following Table 5.1 specifies the minimum particular requirements/tests to be carried out
at the given frequency. Where appropriate, ISO 4422 shall be followed with a factor of safety
2.5 for both specification and test method. The standards mentioned (latest at time of Tender)
here are for specific compliance. Nevertheless this in no way replaces the Contractors and
any other organization's testing regime. All the test Certificates shall be retained for at least
10 years for any inspection and auditing.
The percentage of PVC in the pipe shall not be less than 90% when tested by a loss on
ignition test. The K value that is used in designing the network is generally 0.06, as per
Colebrook and White Designing charts and the pipes supplied shall possess this value of
friction co-efficient.
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Pipes shall be completely circular and no-ovality or bending from straightness is permitted.
If any random test fails in any property the batch from which the sample was taken shall be
rejected and immediately removed from the site. In addition three (3) further samples from
batches identified by the Engineer shall be tested and if any one of these three (3) further
samples fails then the supplier(s) of the materials shall no longer be considered acceptable
and all material from the supplier(s) shall be removed from site and the Contractor shall
submit details of alternative supplier(s) all at no cost to the Employer.
Any discrepancy/contradiction among/within Specifications, Standards, Drawings, etc.
immediately shall be brought to the notice of the Engineer for further clarification.
Test Method
Density
Marking
DIN 8062
DIN 8062
ASTM D792
Visual
DN 8061
EN 681-1
ISO 3127
ISO 4422
DIN 8061
ISO 2057
DIN 8061
ISO 6259
ISO 1167
EN 681-1
ISO 3127
ISO 4422
DIN 8061
ISO 2507
ISO 2505
ISO 6259
ISO 4422-2
ISO 3473
DIN 8062
ISO 7686
ISO 3473
ISO 3126
Wall thickness
DIN 8062
ISO 3126
Resistance to Acetone
ISO 3472
ISO 3472
Loss on Ignition
MRS-Value > 10 000 hrs test
Appearance
ISO 4422
DIN 8061
ASTM D2584
ISO/TR 9080
DIN 8061
Opacity
H2SO4 Resistance
Outer Diameter
Freq.
Test
Remarks
Freq. Legend: A-Every Shift; B-Monthly; C-Yearly; D-Once a Contract; E-5 Yearly;
F-Every Pipe
Class 10
Class 10
Class 10
Class 10
Class 16
Class 16
Class 16
Class 16
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5.6
The maximum sand content in the structural wall of storm water drainage, foul
sewerage and all pressure pipes shall not exceed the allowed limit. Sand shall not be
permitted in the inner chemical resistant layer.
If the manufacturer prefers not to use a veil tissue of ECR or C glass, then it shall be
replaced it with only a vinyl ester resin.
No pigments or dyes may be incorporated into the laminate and no sand fillers may be
present in the inner chemical resistant layer. Pipes and fittings for pressure mains shall not
incorporate sand in outer structural layer. High purity silica sand may be incorporated into the
structural layer of pipes and fittings for gravity flow application and diameters greater than
400mm though under no circumstances will the sand content exceed 30%. All other gravity
mains shall not incorporate sand in the structural layer.
The inner chemically resistant layer (liner) shall be composed of either a vinyl ester Derakane
411-45 from Dow Chemicals or Repoxy R-802 from Showa High Polymer or exact equivalent
even in raw materials used. This inner layer shall have a minimum thickness of 2mm for pipes
conveying foul or effluent water and 1mm for pipes conveying storm or clean water and the
inner surface shall be reinforced with 'C' glass. The resin content by weight reducing form
approximately 90% at the inner surface to 65% - 75% at the outer surface of the liner.
The outer structural layer shall be composed of isophthallic resin, resistant to mineral acid of
PH lower than 2.0, reinforced with 'ECR' (electro corrosion resistant) glass rovings, for pipes
conveying foul or effluent water or 'E' glass rovings for pipes conveying storm or clean water
as appropriate to give a final product of sufficient strength to meet the tensile and flexural
requirements of the pipe. The exterior surface shall be relatively smooth with not exposed
fibres or projections.
Where the Engineer has accepted use of a manufacturing process which precludes the
possibility of liner pre-gelling, an acid resistant grade 'ECR' glass reinforcement shall be used
for pipes conveying foul or effluent pipes, 'E' glass for pipes conveying storm or clean water.
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The results of the strain-corrosion tests carried out in accordance with ASTM-D3681 whilst
the pipe is exposed to 10% sulphuric acid at a temperature of 50C shall indicate that the pipe
has lifetime of 60 years under operating conditions.
5.6.1
Testing
The following tests shall also be carried out by pipe manufacturers at their works. The results
of these tests shall be made available to the Engineer on request. The Engineer shall also be
allowed to witness some or all those tests.
-
b.
c.
d.
Joints for gravity application 1 joint in every 100 pipe/fitting produced shall be
tested in accordance with ASTM-D3262-81.
e.
Joints for pressure application 1 joint in every 100 pipe/fitting produced shall be
tested in accordance with ASTM-D3517-81
Raw materials - All raw materials shall be tested by sampling for consistency to their
Specification. No change of raw material source shall be permitted for a particular
application.
Stiffness - Test shall be carried out to ASTM-D2412 and at a frequency of 1 pipe in 30.
Beam Strength - Tests shall be in accordance with ASTM-D3262 for gravity pipe and
ASTM-D3517 for pressure pipe and at a frequency of 1 pipe in 100 shall apply.
Cure of pipe - A Barcol Hardness test for cure of internal and external surfaces shall be
made on a minimum of 1 pipe in 30. A minimum figure of 85% of the resin supplier's
recommended hardness shall be required.
5.6.2
The maximum pressure attained in the pipeline inclusive of surge shall not exceed the
maximum sustained working pressure rating of the pipe.
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-
The surge pressure amplitude (i.e. the difference between the maximum and minimum
surge pressures) shall not exceed one half of the maximum sustained working pressure
of the pipe.
The pipe shall have a minimum stiffness of 10,000 N/m for depth greater than 8m and
5000 N/m for a depth of less than 8m.
The maximum long term diametrical deflection shall not exceed 5%.
Wall strains shall be limited to values declared by the manufacturer on the basis of long
term performance test information. Typically, these shall be a maximum of 0.5% when
calculating wall strains using the formula.
e = Df. (d/D) (t/D)
where,
e = strain
d = diametrical deflection in mm
t = pipe wall thickness in mm
D = pipe diameter in mm and
Df is a factor primarily dependent on the ratio of pipe stiffness to soil stiffness on
the bedding. The values of Df to be adopted shall be as follows:
Pipe Stiffness (N/mm2)
Df
5,000
10,000
30,000
5.6.3
6
5
4
Details of all resins to be used in the manufacture including the name, manufacturer,
type and properties.
also be given.
-
Details of glass fibre including type, name of manufacture and tex of rovings.
Details of all aggregates used in the manufacture including a sieve analysis and particle
gradation curve for each aggregate.
Details of joints and rubber rings or gaskets including ring or gasket manufacturer's
name, type, and reference number, rubber type and hardness, calculations to show that
the stretch and compression of the ring will be within the range recommended by the
manufacturer. A copy of these recommendations and fully dimensioned drawings of
joints. These drawings shall show the main pipe barrel and the complete joint between
two pipe ends. Dimensions of internal diameter, wall thickness, length of joint and the
extent of all shaping, cut outs etc., should be indicated on the drawing together with the
manufacturing tolerances on these dimension for each class of each diameter of pipe.
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5.6.4
All details should be provided relating to the handling and storage of GRP pipes
including:
a.
b.
site transport
c.
lifting methods
Full details with sketches of installation procedures in open trench and such other
methods of pipeline construction proposed including:
d.
excavation widths and bedding depths appropriate to native soil types and
bedding classes proposed.
e.
f.
g.
bedding backfill and compaction procedures for each class of bedding material.
Details of the bedding materials required by the pipe manufacturer together with a
grading curve and/or sieve analysis of each in tabular form and the degree of
compaction to be achieved by the Contractor.
Details of in-situ joint construction involving hand lay-up butt and wrapped joints.
Procedures for building the pipes into concrete structures, together with sketches
showing short lengths, concrete surround etc.
5.6.5
Tests include long term stiffness, deflection and creep, flexural test, hydrostatic
pressure, corrosion resistance, longitudinal and hoop tensile strength and impact
resistance. The external pressure resistance shall be determined in accordance with
ASTM 2924.
The results of type tests appropriate to the proposed products shall be used to
determine the properties of pipes.
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-
Quality control tests shall be carried out on raw materials (e.g., resins, aggregates,
glass) as well as on laminate specimens, and shall include but not be limited to visual
inspection, checking of dimension, pressure tests etc.
No product from any source shall be incorporated into the Works without the successful
completion of all type tests, including HDB, Strain Corrosion, Creep, and Impact Tests,
under the direct supervision of the Contractor and the Engineer or conducted by the
competent independent Authority to the satisfaction of the Engineer.
Test
Visual Inspection
Standard.
ASTM D 2563 /
DIN 19565(*)
Freq.
100%
Dimensional Check
ASTM D 3567 /
DIN 19565(*)
100%
3
4
Water Absorption
Barcol Hardness
ASTM D 570
ASTM D 2583
1%
100%
5
6
Loss on Ignition
Initial Longitudinal Unit
Tensile Strength by
Strip or Beam
Joint Tightness
ASTM D 2584
BS 5480,
Appendix A or B /
DIN 16869, Part II
(*)
ASTM D 2990 / D
1599
ASTM D 4161
Hydrostatic Pressure
BS 5480,
Appendix K
10
BS 5480,
Appendix H,
Method B
11
12
13
Creep
External Pressure
BS 5480,
Appendix J
DIN 16869
ASTM D 2924
14
Strain Corrosion
ASTM D 3681
15
Hydrostatic Design
Basic
ASTM D 2992,
Procedure B
16
BS 5480,
Appendix L
RI4326-D905-R3-0021
4%
1%
Remarks
Acceptance level-II (Table 1),
ends shall be sealed with 2 layers
Vinyl Ester Resin
Make a series of at least four
readings, approximately equally
spaced and within 5% accuracy
Part 1, Table 2-18
Min. 35 and/or 90% of resin
manufacturers declared value
Liner, structural wall and overall
Acceptance Range Table 2
1%
1%
10% for
gravity
100% for
pressure
pipelines
4%
1%
1%
1 / six
months
One set / 3
years or at
the change
of the raw
material
source
Page 30 of 44
Controlled at temperature of 40
C for minimum one set of tests
consisting of 18 testing
specimens
Controlled at temperature of 40
C for minimum one set of tests
consisting of 18 testing
specimens
Controlled at temperature of 40
C for minimum one set of tests
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No.
17
Test
Under Ring Deflection
(Creep)
Chemical Resistance
(Alkaline Environment)
Standard.
Freq.
ASTM D 3262
Remarks
consisting of 18 testing
specimens
Controlled at temperature of 40
C for minimum one set of tests
consisting of 18 testing
specimens under pH12
b.
The procedure, medium and acceptance criteria for testing of GRP products shall
be accepted by the Engineer prior to commencement of tests.
c.
Dimensions
d.
e.
f.
The length shall be measured with a steel tape or gauge having graduations of
1mm or less.
g.
The wall thickness, length, diameter and squareness of pipe ends shall be
measured for each pipe and fitting. The dimensions shall not deviate from the
tolerances specified.
Stiffness
h.
At least one pipe out of each batch of 30 pipes (or less), shall be tested to
determine the initial specific stiffness.
i.
j.
Specimens from pipes of 10,000 N/mm2, nominal initial stiffness shall be based
on:
k.
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l.
to DN > 200mm
m.
to all DN
n.
Specimens from pipes of 5,000 N/mm2, nominal initial stiffness shall be based
on:
o.
to DN < 200mm
p.
q.
r.
All percentages (%) deflection stated above are of the nominal diameter (DN).
to DN > 200mm
to all DN
Barcol Hardness
t.
A minimum of one pipe for every 30 pipes manufactured shall undergo a Barcol
hardness test in accordance with BS 4549: Part 1: Appendix A.
u.
v.
A minimum of one pipe of each class and diameter of pipe shall be tested,
The sample pipe shall also withstand a commercial acetone test on the internal
portion of the laminate.
Loss on Ignition
w.
Joint Tests
x.
A minimum of two pipes out of 100 pipes shall be joined and tested subject to
the following:
The test pressure shall be as specified under hydraulic test.
An external test pressure of 1.0 bar (gauge) shall be applied to two sections of
pipe assembled with a deflected joint to check the water-tightness of the joint.
The deflection during the joint test shall be 1.5 for DN <600mm and 0.5 for DN
>600mm.
Visual Inspection
y.
Each pipe and fitting shall be subjected to a complete visual inspection before
shipment and after off loading at site.
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z.
For pressure pipes a Burst Test shall be carried out in accordance with BS 5480
to determine the initial circumferential tensile strength of the pipe.
Failure of Tests
aa.
If any random test fails in any property then the batch from which the test sample
was taken shall be rejected and additionally 3 more random samples shall be
tested and if any one of these 3 fails the use of any batch of the tested product
shall be suspended and the Contractor shall submit evidence to the Engineers
satisfaction supporting further use of the product or an alternative in the Works.
5.6.6
5.7
UNITS
mm
m
m
kN/m
kN/m
kN/m2
mm
mm
%
%
%
%
%
%
kN/m'
kN/m'
GN/m'
GN/m2
kN/m2
kN/m2
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PIPE LAYING
6.1
GENERAL
Where socketed pipes are required to be laid on a granular or sand bed, or directly on a
trench bottom, joint holes shall be formed in the bedding material or final excavated surface to
ensure that each pipe is uniformly supported throughout the length of its barrel and to enable
the joint to be made.
Pipes shall be laid on setting blocks only where a concrete bed or cradle is used.
Where pipes are required to be bedded directly on the trench bottom, the final excavated
surface shall be trimmed and levelled to provide even bedding of the pipeline and shall be
free from all extraneous matter that may damage the pipe, pipe coating, or sleeving.
No protective cap, disc or other appliance on the end of a pipe or fitting shall be removed
permanently until the pipe or fitting which it protects is about to be jointed. Pipes and fittings,
including any lining or sheathing, shall be examined for damage and the joint surfaces and
components shall be cleaned immediately before laying.
Suitable measures shall be taken to prevent soil or other material from entering pipes, and to
anchor each pipe to prevent flotation or other movement before the Works are complete.
Where pipeline marker tape is specified, it shall be laid between 100 mm and 300 mm above
the pipe or as specified elsewhere in the Technical Specifications and Drawings.
Before any pipe is lowered into place, the bedding shall be prepared and well compacted so
that each length of pipe shall have a firm and uniform bearing over the entire length of the
barrel.
Pipe shall be laid in straight lines both in the horizontal and vertical planes, between
manholes or the placement of pipe shall comply with following requirements
-
Each pipe shall be plumbed to its correct line and directly and accurately sighted by
means of a laser positioning system or boning rods and sight rails fixed to secure posts
which shall be set up not more than 20 m apart.
Alternative methods of locating and leveling pipelines may be allowed subject to the
agreement of the Engineer.
Any pipe which is not in true alignment, both vertically and horizontally, or shows any undue
settlement after laying, shall be taken up and relaid correctly by the Contractor.
The trench shall be kept completely dry.
In no case shall pipes be jointed before being lowered into position.
The gasket should be positioned and lubricated prior to jointing.
The pipes shall be laid and bedded in granular bedding material except where concrete
bedding or protection is required. The granular material shall extend from not less than 150
millimetres beneath the pipes to 150 millimetres above the crown of the pipes or as directed
by the Engineer. Subsequent filling of the pipe trench shall be carried out as detailed in this
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Section of the Technical Specifications, as shown on the Drawings or as directed by the
Engineer.
GRP pipes shall, unless otherwise directed by the Engineer, be laid on a special bedding
material. The space below the barrel of the pipes shall be filled with special bedding material
to the full width of the trench in layers not exceeding 150mm in thickness. After pipe laying,
between the pipe and the undisturbed sides of the trench up to a depth of 150 mm above the
top of the pipe. The minimum thickness of the special bedding below the barrel of the pipe
shall be 250 mm or as directed by the Engineer. Where a manufacturer requires greater
thickness of special bedding below, around and over the pipes than those specified herein the
manufacturers requirements shall be deemed to have been allowed for in the rates for
bedding.
Where GRP pipes are built into a rigid structure; e.g., manhole or a pumping station, the first
100mm of pipe at entry to the structure shall be surrounded by an agreed flexible material.
Flexible joints shall be incorporated adjacent to structures
Where short GRP pipes are detailed these shall be factory made. Cut ends shall be sealed
with two layers of resin, the second layer being paraffin wax filled to ensure full cure.
Where GRP pipes are required to surrounded with concrete, all necessary precautions shall
be taken to ensure that maximum allowable deflections are not exceeded.
6.2
PIPE BEDDING
Bedding for pipes shall be constructed by spreading and compacting granular bedding
material over the full width of the pipe trench. After the pipes have been laid, additional
material shall, if required, be placed and compacted equally on each side of the pipes, and
where practicable, this shall be done in sequence with the removal of the trench supports.
6.3
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Nominal bore of pipe (mm)
Exceeding 1200
Rapid hardening cement shall not be used in concrete for the protection of plastics pipe.
Plastics pipes shall be wrapped with a layer of plastic sheeting complying with a composition
in accordance with Clause 3 of BS 6076 and a nominal thickness of 125 microns before being
surrounded by concrete.
6.4
6.5
BACKFILLING
Backfilling shall, wherever practicable, be undertaken immediately the specified operations
preceding it have been completed. Backfilling shall not, however, be commenced until the
works to be covered have achieved a strength sufficient to withstand all loading imposed
thereon.
Backfilling around existing structures shall be undertaken in such manner as to avoid uneven
loading or damage.
Filling material to excavations shall be deposited in layers not exceeding 250mm
unconsolidated thickness and compacted to 95% modified dry density.
Where the excavations have been supported and the supports are to be removed, these,
where practicable, shall be withdrawn progressively as backfilling proceeds in such a manner
as to minimise the danger of collapse. All voids formed behind the supports shall be carefully
filled and compacted.
6.6
6.6.1
Gullies
Gullies shall incorporate rodding eyes. Rodding eyes shall be fitted with rubber stoppers
during normal operation.
All gullies shall be trapped to prevent unwanted odours escaping from the drain.
All gullies shall in corporate aluminium silt buckets.
The Contractor shall ensure that the gully outlet and the outlet pipework are compatible.
Gully covers, gratings and frames shall comply with the relevant provisions of BS 497: Part I
or BS EN I24.
The class of gullies covers, gratings and frames shall be as described in the Project
Specification or as shown on the Project Drawings.
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6.6.2
Pre-formed Gullies
Precast concrete gullies shall comply with the relevant provisions of BS 5911: Part 2.
Vitrified clay gullies shall comply with the relevant provisions at BS EN 295: Part I or BS 65.
Polypropylene gullies shall be of a type detailed in the Project Specification or shown on the
Project Drawings and shall be obtained from a reputable manufacturer as agreed with the
Engineer.
Cast iron gullies shall be of a type detailed in the Project Specification or shown on the Project
Drawings and shall be obtained from a reputable manufacturer as agreed with the Engineer.
Pre-formed gullies shall be bedded and surrounded with Grade C20 concrete to the thickness
described in the Contract Documentation.
Frames shall be bedded in mortar on two courses of Class B engineering brickwork or precast
concrete gully cover slabs. Precast concrete gully cover slabs shall comply with the relevant
provisions of BS 59 II: Part 2.
6.6.3
Manhole
The Contractor shall prepare a standard record sheet for every manhole and structure for
inclusion with the as-built drawings.
Manholes shall be constructed as shown on the contract Drawings and at the locations
indicated thereon or at such other locations directed by the Engineer.
The blinding concrete shall be mass concrete Grade 20SRC and shall be protected with
membrane tanking systems. The necessary period for setting, as recommended by the
manufacturer, shall be allowed before beginning other works to complete the construction of
the manhole.
The cover slabs shall be surmounted by cast iron manhole covers and frames of the quality
specified. The covers in roads and paved areas shall be accurately set on precast concrete
brickwork to the level and slopes of the roads or pavements.
In the case of shallow manholes, the cover and frame may be cast directly monolithic with the
reinforced concrete cover slab and projecting up by 50 mm as shown on the Contract
Drawings.
The interior face of manholes and access shafts shall be prefabricated GRP liners at least
6mm thick permanent lining.
Benchings and channels shall be preformed, inverted and filled with concrete. Alternatively,
the GRP lining may be applied in-situ after constructing the benching.
GRP Lining to walls shall incorporate lugs moulded onto the outside face at 500 mm centres
to allow bonding to the concrete surround. The lining shall have adequate strength to
withstand handling and shall not buckle or distort during pouring of the concrete surround.
Internal bracing may be used during pouring to maintain circularity and verticality.
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Precast cover slabs shall incorporate a performed flat sheet of GRP on the soffit, bonded to a
circular GRP tube to form the access opening. Both linings shall incorporate lugs moulded
onto the surface to allow bonding to the concrete.
Joints in the lining tubes shall not be permitted.
Joints between preformed GRP benchings and lining tubes shall be made using an external
sleeve 200 mm long bonded onto both units, and then bandaged using suitable resign and
chopped strand mat.
IF GRP linings to benchings are to be formed in situ the surface of the wall lining tube shall be
lightly abraded over a height of 150 mm from benching level. A fillet of 50 mm radius shall
then be formed of vinyl ester paste at the junction of benching and wall.
Top surface of benchings shall incorporate silica sand to form a non- slip surface.
The precast cover slab shall be seated on the walls using sand/cement mortar. The joint shall
be raked out 15mm deep on the inside face and pointed with an acceptable pitch extended
polyurethane sealant.
The Contractor shall provide the Engineer with a 7 year unconditional guarantee against
failure of all GRP linings whether caused by defective materials or workmanship. The
guarantee shall be valid from the date of completion of the installation and must be delivered
to the Engineer before the issue of the Final Completion Certificate.
All manholes shall be watertight on completion and where leakage is discovered the
Contractor shall perform such work and provide all materials as are necessary to render such
faulty work watertight. The Contractor is warned that he shall preclude rubbish and debris
being deposited in the manholes during the course of construction and he shall take the
necessary measures to ensure that the manhole is kept clean both during construction and
after completion.
Back filling around manholes in roads shall be carried out using granular material as directed
by the Engineer.
Step iron if shown on the Drawings shall comply with the relevant provisions of BS 497: Part 1
and have a minimum clear opening of 600 mm diameter if circular or 600 x 750 mm if
rectangular. All covers shall have closed key ways.
6.7
6.7.1
General Requirements
Connection to government mains shall be done at manholes. Pipe saddles and oblique
junctions will not be permitted.
Where possible and practicable, connections shall be made to future connection ports in
existing Government manholes. The caps on future connection ports to which connections are
made shall be cleaned and delivered to the government stores on completion of the work.
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Where it is not possible or practicable to utilise future connection ports in existing manholes,
connections shall be made by either breaking into existing manholes or constructing new
manholes on existing mains.
If it is necessary to break into an existing manhole, the Contractor shall break into the
manhole wall, insert pipework, break out the existing benching, construct benching to suit new
connection and make good. If necessary, the Contractor shall relocate the access ladder and
the cover slab to suit the new benching layout .
Manholes built on an existing Government mains shall be constructed in accordance with the
relevant Authorities requirements or to the requirements of the technical Specifications,
whichever is the more stringent, but all to the approval of the relevant Authority. On
completion, such manholes shall become the property of the Government.
The Contractor shall be responsible for all over-pumping operations associated with making
connections to Government mains.
6.8
THRUST BLOCKS
Though standard drawings indicate typical thrust block details the Contractor should ensure
the proposed thrust blocks will be capable of handling the maximum system operating
pressure during the system performance period. All details of the thrust blocks shall be
submitted by the Engineer by way of shop drawings prior to commencement of construction.
Ductile Iron Pipes have specific requirements for thrust blocks and these should be referred to
above.
6.9
VALVES
6.9.1
General
Valves shall be capable of withstanding corrosion in the ambient conditions.
Nylon or other thermoplastic materials liable to attack shall not be used where hydrogen
sulphide is likely to be present.
All valve waterways shall be coated internally with a solvent free epoxy or polyester lining of
100% solid content to be applied at the place of manufacture. The lining shall be of 250
micron nominal thickness and holiday free.
All valves will normally be witness tested at works.
Unless otherwise specified all valves and penstocks shall be anti-clockwise opening and the
maximum effort required, applied at the circumference of the hand wheel to operate the
valves against the maximum unbalanced head shall not exceed 55kg.
All hand wheels shall have the words "to open" and "to close" in Arabic and English with
arrows indicating the direction of rotation cast on and shall be coated in plastic, nylon or other
acceptable materials in order to withstand the ambient conditions.
Unless otherwise specified or agreed spindles and extension spindles shall be of stainless
steel Grade 316 S16.
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Extension spindles, where required, shall be connected by suitable muff type couplings
manufactured from stainless steel grade 315S16. The muff couplings shall be supplied drilled
with nuts and bolts for connection to the spindles.
A clear polycarbonate tube shall be securely fitted to protect the thread of rising spindles.
The nuts shall be of gunmetal or synthetic material and mating surfaces of gates and bodies
shall be of gunmetal, copper alloy or synthetic material.
All fixing brackets, bolts and nuts, washers, etc. shall be SS grade 316 S16.
Where "Operation by Tee Key" is specified the valve or penstock shall be supplied with a
suitable yoke with a squared cap of standard size to receive the tee key.
The key shall be supplied at the rate of one key per two valves or two penstocks unless the
valve or penstock is to be installed in an isolated location in which case one key shall be
supplied for each fitting location.
Before delivery to site all working surfaces shall be thoroughly cleaned, and, if metal,
protected by grease.
Packing must be sufficient to ensure complete protection of the fitting during transit and
storage.
Valves under 300 mm diameter together with all hand wheels and other easily detachable
items on both valves and penstocks are to be packed in timber packing cases and properly
bound with steel packing bands.
All valves of 300 mm and over are to be protected with wood or plywood discs or flanges
together with straw rope and hessian wrapping.
6.9.2
Check Valves
Check valves three inches (3") and above shall be double flanged single door swing type
having ductile iron body and gunmetal seat to BS1400 .Pressure Rating to be PN 16 or more.
All valves shall be coated with electrostatically applied (at 2250C) epoxy internally and
externally to average DFT 300 microns for protection against corrosion of body components.
All nut bolts to be of stainless steel grade 316/ A4-70.
Check valves of two inches (2") and smaller shall be spring type manufactured from Brass or
Bronze. Inlet and outlet to be BSP female threaded. The spring shall be of stainless steel.
Pressure rating shall be PN16 or more.
The face to face lengths of the valves shall be either 2 x ND + 100 mm or to an agreed
international standard, the longer length to be allowed for in all cases using make up pieces
where necessary to achieve the required lengths.
All valves shall be clearway, and lugs provided on screwed seats, etc., for assembly purposes
shall be removed.
Sewerage valves shall, unless impracticable through size or otherwise specified shall be
capable of passing 90 mm dia. solids.
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6.9.3
Gate Valves
Gate valves shall conform to the requirements of the WDD and SDD Standard Specifications.
6.9.4
Air Valves
Air valves shall conform to the requirements of the WDD and SDD Standard Specifications
and the following requirements.
-
Automatic double orifice air vents shall be provided at all high points on the system. Air
valves and other similar items shall confirm to BS 2591. Automatic air valves shall have
non-corrosive floats in chambers with clear space ensuring blockage free operation. All
components for the air valve actuating mechanism including lever shall be stainless
steel.
The body and cover of the valve should be of bronze or ductile iron with phenolic primer
coating. Nozzles with seals and actuating mechanism to be located in the removable
upper plate connected to the valve body using stainless steel (grade 316/A4) bolts.
Valves shall be coated with epoxy internally and externally to average DFT 300 microns
for protection against corrosion of body components. All nut bolts to be of stainless
steel grade 316/ A4-70.
Unless higher pressure ratings are required for the pipeline, or otherwise indicated in
the Contract Documentation air valves shall have a nominal pressure rating of 10 bar
which shall be marked on the valve body and shall be designed for a liquid temp. of
500C and air temperature of 700C.
Air valves for pumped pressure pipelines shall be the high pressure Dual large orifice type.
The following shall be used as a guide for the general sizing of large orifice air valves:
200
300
350
450
600
900
1000*
20
25
50
80
100
150
200
100
100
100/125 100/125
125
125/200
Ball size (mm)
* For larger mains air valves may be fitted in clusters of two or more as required.
150/200
For mains 100mm diameter or less single, small orifice type standard air valves having a
nominal 25mm male thread inlet and with a ball size of 100 mm shall be used.
The test pressure for different components of the air valves shall be as follows:
Body
20 bar
Seat
10 bar
Ball/Float
10 bar
The materials of construction for air valves shall be as follows :Body, Cover & Duct Cover:
Ball/Guide:
Seat:
Air Release Nipple:
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All Bolts:
All components shall be highly resistant to corrosion due to sewage and very high
concentrations of H2S and other gases. All internal components shall be strong in design and
of stainless steel grade 316 S16.
The access cover for air valves shall be in such a position that the valves could be easily
removed for repair/maintenance.
The siting of the air valves shall be at locations shown on the Drawings or as directed by the
Engineer on site.
6.9.5
Penstocks
Fixings shall be of the drilled anchor type and made of stainless steel.
All penstocks shall be suitable for an on/off seating head of 10m minimum but in all instances
shall be less than 1.5 the maximum working head.
The size of the penstock to be used in any particular location shall be as described in the
Contract Documentation and agreed with the Engineer.
The frame, doors, sealing faces and spindles of each type shall be as specified in the
appropriate clauses herein.
Unless otherwise described in the Contract Documentation all penstocks shall be provided
with hand wheels of adequate diameter with suitable gearing where necessary to ensure that
the required operating force applied by hand does not exceed 55 kg.
Hand wheels shall have the words To Open and To Close in Arabic and English with arrows
indicating the direction of rotation cast on them. The direction of closing shall be clockwise
and a vandal / weatherproof, clear polycarbonate tube cover shall be securely fitted to the
thread of rising spindles. The tube shall be clearly and permanently engraved to indicate the
position of the penstock.
Spindles shall have machine cut robust trapezoidal or square form threads as necessary.
They shall be of stainless steel. Extension spindle coupling shall be of the muff type and they
shall be drilled and provided with a stainless steel nut and bolt for securing the spindle to the
penstock spindle head which likewise be drilled to take the bolt.
All penstocks shall be of the rising type unless otherwise stated. Headstock shall be provided
except in cases where the handwheels can be mounted on the penstock frames. Unless
otherwise stated for penstocks of 300mm (square or circular) or more thrust tubes shall be
provided. For all motorised/actuator operated penstocks thrust tubes shall be provided
between the penstock frame and headstock in order to absorb the thrust in both directions of
operation. Thrust tubes shall incorporate all necessary fixing brackets and spindle guide
plates.
Permissible rates of leakage under specified working head shall be as follows:
-
Off seating installation: 30 litres per meter of slide perimeter per hour.
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The slide perimeter shall be measured as the total length of contact faces between the gate
and frame in the closed position.
All materials used in the manufacture of penstocks shall conform to international standards
agreed with the Engineer if not otherwise specified.
6.9.6
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End of Specification
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