DANCO AQUAFLEX HDPE (PE100)

PRESSURE PIPELINE INSTALLATION

& GOOD PRACTICES GUIDE
A methodology of model pipe installation,
specification and practice for Kenya
 Danco Aquaflex PE100 Pressure Pipeline Installation Specification & Good
Practices Guide
Contents
1 SCOPE OF SPECIFICATIONS ............................................................................................................. 4
2 APPLICABLE STANDARDS AND CODES ............................................................................................ 4
3 GENERAL TECHNICAL REQUIREMENTS ........................................................................................... 4
4 PRE-CONSTRUCTION SURVEY ......................................................................................................... 5
5 RIGHT-OF-WAY (ROW) .................................................................................................................... 5
5.1 General.................................................................................................................................... 5
5.2 Crossings ................................................................................................................................. 6
5.3 Clearing, Grading, Backfilling and Surveying of the ROW ....................................................... 6
5.4 Stripping, Storage and Reinstatement of Topsoil ................................................................... 7
5.5 Fences and Barriers ................................................................................................................. 7
5.6 Removal of Debris ................................................................................................................... 8
5.7 Restricted ROW ....................................................................................................................... 8
5.8 ROW Damages ........................................................................................................................ 8
5.9 Provision of Detours................................................................................................................ 8
5.10 ROW in Rough and Rocky Areas ............................................................................................. 8
5.11 ROW in Sand Dune and Sandy Areas ...................................................................................... 8
5.12 ROW in Areas Having Poor Ground Conditions ...................................................................... 9
5.13 Granular Material for ROW ..................................................................................................... 9
5.14 Minor Route Deviations .......................................................................................................... 9
6 HANDLING, HAULING, STRINGING AND STORAGE ......................................................................... 9
6.1 Pipe Materials ......................................................................................................................... 9
6.1.1 Receipt of Pipe Materials ................................................................................................ 9
6.1.2 Storage and Handling of Pipe Materials ......................................................................... 9
6.1.3 Care of Other Materials ................................................................................................ 11
7 TRENCHING ................................................................................................................................... 11
7.1 Excavation ............................................................................................................................. 11
7.2 Normal Cover and Trench Dimensions ................................................................................. 11
7.3 Minimum Pipe Cover Requirements ..................................................................................... 12

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 7.4 Extra Depth and Clearances .................................................................................................. 12
7.5 Crossing and Laying Adjacent to Existing Utilities................................................................. 12
7.6 Trenching Across or Along Roads and Tracks ....................................................................... 13
7.7 Grading and Finishing of Trench or Formation ..................................................................... 14
8 BACKFILLING.................................................................................................................................. 14
8.1 General.................................................................................................................................. 14
8.2 Pipe Bed and Surround ......................................................................................................... 14
8.3 Geotextile Filter Fabric .......................................................................................................... 16
8.4 Selection and Placing of Backfill Materials ........................................................................... 16
8.5 Backfill and Reinstatement of Trenches in Roads and Tracks .............................................. 17
9 NON-DISRUPTIVE CROSSINGS ....................................................................................................... 17
9.1 General.................................................................................................................................. 17
9.2 Construction Methods .......................................................................................................... 17
10 PIPE LAYING .............................................................................................................................. 18
10.1 General.................................................................................................................................. 18
10.2 Minimum Allowable Bending Radius .................................................................................... 18
11 PIPE JOINTING ........................................................................................................................... 18
11.1 General.................................................................................................................................. 18
11.2 Pipe Jointing Personnel ......................................................................................................... 19
11.3 Method Statement................................................................................................................ 19
11.4 Electro-fusion Jointing .......................................................................................................... 20
11.5 Electro-fusion Joint Inspection.............................................................................................. 20
11.6 Butt Fusion Jointing............................................................................................................... 21
11.7 Butt Fusion Joint Inspection .................................................................................................. 21
11.8 Testing of Fusion Joints ......................................................................................................... 22
12 TYING-IN .................................................................................................................................... 22
12.1 Joining Unconnected Sections .............................................................................................. 22
12.2 Tie-ins after Hydro-testing .................................................................................................... 22
13 RESTORATION OF THE CONSTRUCTION RIGHT-OF-WAY .......................................................... 23
13.1 General.................................................................................................................................. 23
13.2 Progress of ROW Restoration ............................................................................................... 23
13.3 Pipeline Markers ................................................................................................................... 23
13.4 Equipment Nameplates ........................................................................................................ 23

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14 DETECTABLE WARNING TAPES ................................................................................................. 23
15 HYDROSTATIC TESTING ............................................................................................................. 24
15.1 General.................................................................................................................................. 24
15.2 Method Statement................................................................................................................ 24
15.3 Outline Test Procedure ......................................................................................................... 24
15.4 Test Result ............................................................................................................................. 26
15.5 Notes on Test Equipment ..................................................................................................... 27
15.6 Differences in elevation ........................................................................................................ 27
15.7 Test pressures at elevated temperature............................................................................... 27
15.8 Additional Notes ................................................................................................................... 28
16 DISINFECTION AND FLUSHING OF WATER PIPELINE................................................................. 28
16.1 General.................................................................................................................................. 28
16.2 Method Statement................................................................................................................ 28
16.3 Disinfection and Flushing ...................................................................................................... 28
16.4 Acceptance Criteria for Disinfection ..................................................................................... 29
17 CONNECTION TO EXISTING WATER PIPELINES AND SERVICES ................................................. 30
18 PIPELINE COMMISSIONING ....................................................................................................... 30
19 QUALITY ASSURANCE/QUALITY CONTROL................................................................................ 30
20 CONSTRUCTION RECORDS ........................................................................................................ 31
20.1 General.................................................................................................................................. 31
20.2 Brief Daily Reports ................................................................................................................ 31
20.3 Detailed Weekly Reports ...................................................................................................... 31
20.4 Detailed Monthly Reports ..................................................................................................... 31
20.5 Completion Report................................................................................................................ 32
20.5.1 General .......................................................................................................................... 32
20.5.2 As-Built Drawings .......................................................................................................... 33

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SPECIFICATION FOR CONSTRUCTION, TESTING & COMMISSIONING OF PE100 PRESSURE
PIPELINE SYSTEMS

1 SCOPE OF SPECIFICATIONS
This specification covers minimum requirements for the construction, installation and testing of
pipelines comprising PE100 (High Density Polyethylene - HDPE) pipes and fittings.

2 APPLICABLE STANDARDS AND CODES

Unless otherwise specified the works shall conform to the following standards and other standards
noted elsewhere in this specification.
ISO 4427 Plastics piping systems - Polyethylene (PE) pipes and fittings for water supply
ISO 12176 Plastics pipes and fittings — Equipment for fusion jointing polyethylene systems,
Parts 1 and 2
ISO 21307 Plastics pipes and fittings — Butt fusion jointing procedures for polyethylene (PE)
pipes and fittings used in the construction of gas and water distribution systems
ISO 13953 Polyethylene (PE) pipes and fittings - Determination of the tensile strength and
failure mode of test pieces from a butt fused joint
ISO 13954 Plastics pipes and fittings - Peel decohesion test for polyethylene (PE)
electrofusion assemblies of nominal outside diameter greater than or equal to 90
mm
EN 805 Water supply – Requirements for systems and components outside buildings
EN 12007 Gas supply systems - Pipelines for maximum operating pressure up to and
including 16 bar, Part 2: Specific functional recommendations for PE
EN 12201 Plastics piping systems for water supply and for drainage and sewerage under
pressure – Polyethylene (PE)
EN 12613 Plastics warning devices for underground cables and pipelines with visual
characteristics
AWWA C651 Disinfecting water mains
SFS 3115:E Plastics Pipes Water Tightness Test for Pressure Pipelines (English version of
Finnish Standard)
WIS-4-08-02 Specification for bedding and sidefill materials for buried pipelines

3 GENERAL TECHNICAL REQUIREMENTS

The Contractor shall prepare detailed Method Statements (MSs) for all significant activities and submit
these to the Engineer for approval prior to commencement of the work described by each MS. They
shall describe in detail how the Contractor proposes to perform the different activities required to
undertake the Works whilst ensuring compliance with the specification and all appropriate laws,
regulations and requirements of the relevant authorities.
The Contractor shall take full responsibility for the stability and safety of all operations carried out and
all methods of work adopted. The Contractor shall also take full responsibility for stability and safety

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of all existing facilities, utilities, roads other infrastructure and property affected by the Contractor
undertaking their work.
The Contractor shall be deemed to have inspected the work area(s) and their surroundings and to
have satisfied themselves as to their nature, including sub-surface conditions, hydrological and
climatic conditions, the extent and nature of the work, the materials necessary for the completion of
the work and the means of access to all the work area(s).
The Contractor shall be deemed to have obtained all necessary information related to the risks,
contingencies and all other circumstances that may influence the work.
The Contractor shall, in connection with the work, provide and maintain all lights, safety barriers,
fencing, watchmen and associate facilities required to undertake the works in a safe manner. They
shall also comply with the requirements of Engineer and any relevant authority having jurisdiction
over the works or the safety and convenience of the public or others. The Contractor shall adapt their
method of work to suit any changing conditions on site in order to ensure that the works are
undertaken in a safe manner. Such changes shall however be subject to approval by the Engineer.

4 PRE-CONSTRUCTION SURVEY
Prior to any construction activities the Contractor shall carry out a pre-construction survey to stake
the pipeline centreline and identify all relevant features along the pipeline route. They shall define the
Right-of-Way (ROW) by stakes placed at locations where they shall not be disturbed and from where
the boundary of the ROW can be determined.
The Contractor shall stake the entire pipeline route(s) as per the data available on the alignment
drawings in compliance with the MS be submitted to and approved by the Engineer.
The construction survey controls shall be staked at a maximum distance of 100 m from each other.
The staking shall be based on the markers set along the pipeline route and construction drawings. The
Contractor shall establish references offset from pipeline centreline such that they shall not be
disturbed by the construction works.
The final pipeline alignment shall be subject to approval of the Engineer.

5 RIGHT-OF-WAY (ROW)

5.1 General
The ROW shall have the dimensions indicated on drawings approved by the Engineer. The pipeline
shall be located at the centre of the ROW, unless indicated otherwise.
The Contractor shall co-ordinate with all local authorities and utility owners to obtain the approval for
the ROW.
Prior to any clearing operation the Contractor shall make themselves familiar with all restrictions along
the ROW and shall use their best endeavours to avoid any damage to property and existing
infrastructure on or adjacent to the ROW.
Prior to the commencement of any construction activities in an area the Contractor shall locate and
identify all existing buried facilities, such as cables, pipelines, water mains and sewers etc. including
those not shown on the drawings, crossed or at close proximity to the pipeline. This shall be achieved
by liaison with the relevant authorities, carrying out surface and sub-surface surveys and exposing any
buried utilities by hand excavation, unless exempted in writing by the Engineer.

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Once located, the underground facilities crossed by the pipeline route or running parallel to it within
the ROW shall be clearly marked by methods approved by the Engineer.
The Contractor shall submit a detailed MS setting out the precautions to be taken for avoiding or
preventing damage to existing utilities, fences, roads or other infrastructure, existing above or below
ground or any property adjacent to or crossing the pipeline being constructed. All work carried out in
the vicinity of such infrastructure or property shall be undertaken only after the issue of a permit or
written approval by the relevant authorities.

5.2 Crossings
Crossing of roads, buried services and other infrastructure shall only be permitted after the Contractor
has obtained written approval from the appropriate authorities. The Contractor shall undertake their
work in such a manner as to not interrupt the operation of existing infrastructure and to minimise the
risk of the infrastructure being damaged.
The Contractor shall acquaint themselves with all relevant requirements and regulations of the
authorities responsible for roads, utilities and other infrastructure on or crossing the ROW and obtain
their approval in writing together with all necessary permits before commencing work.
Notwithstanding the provisions of the drawings and specifications, it shall also be the Contractor's
responsibility to ensure that the work is performed in accordance with the requirements of the
relevant authorities. In the event that the requirements and specifications of the authorities are more
stringent than those of the Engineer, then the authorities' requirements shall be followed.
Highways, main roads and their verges shall not be used for loading, unloading or stacking of materials
and/or equipment. For secondary roads, such loading/unloading is permitted only after prior approval
from the relevant authorities. The Contractor shall not close or divert roads without prior approval
from the Engineer and the concerned authorities. The Contractor shall never unnecessarily hamper
the activities of road users.
Any diversion arrangements, if required, shall conform to the requirements of the relevant authorities
and be approved by them.

5.3 Clearing, Grading, Backfilling and Surveying of the ROW

During the preparation of the ROW the Contractor shall, after any removal of top soil, grade the ROW
to provide access to the pipeline during construction, removing sharp high and low points and any
other obstacles that may restrict safe access or prevent the pipeline being laid in accordance with the
specification. Backfill material may be installed on the ROW at low points as needed for vehicle access,
provided that such works do not block the flow of any water. The Contractor shall grade and construct
the ROW so that the trench is excavated in undisturbed ground.
The construction of access roads in the ROW shall be carried out in conjunction with the clearing and
grading of the ROW. After clearing the ROW and when grading has been performed so as to allow
passage of loaded trucks and equipment the Contractor may commence his scheduled work.
The Contractor shall make necessary arrangements such as ramps, culverts and temporary bridges to
carry the access roads across any channels, low level roads and access ways. This shall be accomplished
in such a way as to permit the continued flow of water or traffic use and to preserve the structure of
the channels or roads being crossed by the access road. No existing crossings shall be filled or

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otherwise obstructed without approval of the relevant authority. Such written approval shall provide
to the Engineer prior to commencing any associated work.
The Contractor shall establish any additional survey monuments required and shall maintain and
preserve survey monuments (already staked on ground) such as Bench Marks and
Intersection/Turning Points until the construction is completed. If any Bench Marks are missing the
Contractor shall re-establish them, as directed by the Engineer, to carry out levelling work during
laying or the as-built survey of the pipeline.
The Contractor shall carry out all survey and levelling of line and grade including an as-built survey
necessary to complete the work and shall be responsible for the accuracy of such survey works.
The Contractor shall install distinct markers locating and indicating special points, such as but not
limited to contract limits, warning notices, presence of buried structures, obstacle crossings and any
change of pipe wall thickness including the corresponding chainage, etc.
Markers shall be of a sufficient height and of material and type approved by the Engineer so as to
serve their purpose. The Contractor shall be responsible for the maintenance and replacement of the
reference line markers until the permanent pipeline markers are placed and the as-built drawings are
submitted and approved.

5.4 Stripping, Storage and Reinstatement of Topsoil

Where the ROW passes through agricultural land, roadside verges, plantations, landscaped areas or
any other areas having significant topsoil, the topsoil shall be removed and stockpiled prior to the
grading of the ROW. The depth of topsoil stripped from the ROW shall be determined by the
excavation of trial holes at regular intervals and shall be approved by the Engineer.

Upon completion of the construction works the topsoil shall be reinstated in the areas from where it
was removed, to the satisfaction of the Engineer, the relevant authorities and the land owner, if any.
Any shortfall in material shall be made of with imported topsoil of the same type.

5.5 Fences and Barriers

The Contractor shall install plastic mesh type fencing on either side of ROW where it is required to
ensure safety and non-interference, especially in industrial, commercial or residential areas in the
proximity of roads or other installations. The mesh fencing shall be orange in colour and manufactured
from UV stabilised high density polyethylene or polypropylene. It shall have a minimum weight of 160
gms/m2, a minimum height of 1 m and be regularly supported by steel or timber supports having a top
rail, cable or rope running the length of the fencing.
The Contractor shall provide and install heavy duty modular precast reinforced concrete barriers at
any location where traffic might accidentally encroach on the construction. The design of the barriers
shall follow the typical ‘Jersey’ design, have a minimum height of 0.8 m and be approved by the
Engineer.
Fencing and barriers shall be continuously maintained.
On completion of construction the Contractor shall reinstate any damaged or relocated fencing to
their original condition. The Contractor shall be liable for any damage, claims or actions arising from
breaches made in existing fences.

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5.6 Removal of Debris
The Contractor shall remove all debris, loose rock or other hard material from the ROW and dispose
of it in a manner satisfactory to the Engineer and the relevant authorities.
The Contractor shall be responsible for all surplus material disposals, if any, arising out of clearing and
grading operations.

5.7 Restricted ROW

When the ROW passes through any plantations, roads, overhead or buried services, areas of poor
ground conditions or other confined areas, only the minimum ROW necessary for the actual
excavation of the trench and construction of the pipeline and access road, if any, shall be used. The
Contractor shall perform the work at such places in such a way as to minimise damage to any tree or
plantation. The cutting or removal of trees and plantations shall only be undertaken with the written
approval of the Engineer.

5.8 ROW Damages

The Contractor shall be liable for any and all remedial work required to make good damage to existing
utilities, roads and other infrastructure or property caused by the works. The Contractor shall perform
such remedial work as and when required by the relevant authority, property owner and the Engineer.

5.9 Provision of Detours

At locations where any part of the work is routed along, over, under or across tracks, roads or
highways, the Contractor shall provide and maintain detours, temporary bridges and road controls
including warning lights that may be required by the relevant authorities.
Public travel shall not be unnecessarily inconvenienced nor shall it be wholly obstructed at any time.
The Contractor shall supply watchmen at any location where safety and work operations justify their
use or where directed by the Engineer. They shall maintain detours and shall supply and maintain
lights, fencing, barriers and warning signs wherever necessary, to fully protect the public and facilitate
the smooth running of the project.

5.10 ROW in Rough and Rocky Areas

Wherever rocky terrain is encountered, grading and excavation to prepare the ROW shall be carried
out by ripping, drilling, wedging, chiselling using jack hammers and rock breakers or by other
recognised methods approved by the Engineer. Blasting will not be allowed.

5.11 ROW in Sand Dune and Sandy Areas

The ROW in sand dune and sandy areas shall be graded by the Contractor in compliance with the
relevant drawings and shall be approved by the Engineer. The profile of the graded ROW shall
generally follow the profile of the natural terrain with some minor alterations to enable proper
construction of the pipeline. While grading, any necessary cutting of dune high points shall be
undertaken in order to minimise sharp angles at high points and reduce the risk of the pipeline being
exposed by movement of the dune peak. The cut material shall be generally spread on the sides of the
ROW and filling of low areas shall be minimised. Trenching will follow the general profile of the ROW
as per the cover requirements. Localised sand dunes along the pipeline alignment shall be removed
by the Contractor as a part of his scope of work while preparing the ROW.

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5.12 ROW in Areas Having Poor Ground Conditions
The ROW in areas having poor ground conditions such as swamps, salt flats, sabkha and marsh areas
shall be constructed using a granular material, that shall be placed and compacted to provide a firm
and safe working surface. The type of fill material to be used by the Contractor shall be approved by
the Engineer and shall comply with the specification.

5.13 Granular Material for ROW

Granular material, sometimes referred to as gatch material, to be used for preparing or for stabilising
of the ROW by the Contractor shall be a granular dry soil material with high level of cementatious
content, such as gypsum or clay which when watered, mixed and compacted, gives a firm and solid
mass of material. The compacted material shall not contain loose patches of soil and shall not break
nor erode during normal use or environmental conditions. The Contractor shall also obtain the
approval from the relevant authorities for mining of the material.
The material shall be watered to achieve the optimum moisture content and then compacted to
achieve a density of not less than 90% modified Proctor (AASHTO) density. The compaction shall be
undertaken in layers of no more 200 millimetres by suitable means.

5.14 Minor Route Deviations

The Contractor shall carry out any local realignment of the pipeline route or profile and any associated
design modification as required by the presence of underground structures and / or utilities found
during excavation. Such deviations shall be approved by the Engineer and the relevant authorities.

6 HANDLING, HAULING, STRINGING AND STORAGE

6.1 Pipe Materials

6.1.1 Receipt of Pipe Materials

The Contractor shall procure pipe materials, which shall be taken to include all fittings and accessories
at a designated area, subject to the Engineer’s approval.
Prior to taking delivery from the Supplier, the Contractor shall examine the pipe materials and satisfy
themselves as to the condition of the materials prior to accepting delivery. After taking delivery of the
materials the Contractor shall be responsible for their care and custody and for replacement of any
damaged pipe materials.
Transportation of pipe materials to the construction site is the Contractor’s responsibility.
Pipe material which was found to be damaged at the time of taking over shall be marked and placed
separately and shall only be transported to the site after the defects have been repaired or eliminated,
as agreed with the Engineer.

6.1.2 Storage and Handling of Pipe Materials

The Contractor shall be responsible for handling, hauling, stockpiling, storage and stringing of the pipe
materials together with arranging and paying for storage areas.
The Contractor shall be responsible for providing suitable trucks and equipment in sufficient quantity
to transport the pipe materials in a safe manner that prevents damage.

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Pipe materials shall be stocked, chocked, padded, and secured in position during transportation,
storage and stringing in a manner approved by the Engineer. If pipes or fittings are supplied in bundles
or on pallets, they shall remain so packaged until they are delivered to the location of installation on
site.
Care and attention should always be applied when handling pipe materials, not only for the protection
of the pipe materials but also for the safety of the handling personnel.
Pipe materials shall never be dropped onto hard or uneven surfaces, thrown from vehicles or be
dragged or rolled along the ground.
Where pipe weights exceed practical personnel handling then rope or web slings shall be used with
mechanical lifting equipment. Metal chains, hooks or cables shall never be used.
Pipes shall be transported on vehicles with a flat bed and free from sharp edges or protrusions and
they shall generally be supported over their full length at intervals recommended by the
manufacturer.
Materials shall be stored in accordance with the pipe manufacturer’s recommendations and this
specification.

The storage area should have a relatively smooth, level surface free of sharp stones, debris or other
materials that could damage the pipe or fittings. Where adequate ground conditions do not exist or
when a level gravel bed cannot be prepared, the pipe shall be placed on timber supports evenly
spaced along the pipe length. The support size and spacing shall be as advised by the pipe
manufacturer.

Stacks shall only contain pipes of one size and wall thickness and shall be constructed in a pyramid,
with each successive layer having one less pipe than the layer below. The bottom layer should be
braced to prevent movement and the stack shall not exceed a height of 2.0 m.

Coils should be stored horizontally on pallets and they shall not overhang the sides of the pallets.
Coils may be stacked as ‘silos’ but the height of any silo shall not be higher than 2.0 m.

Pipes materials shall be kept away from lubricating or hydraulic oils, gasoline, solvents or other
materials that may cause damage.
Fittings and accessories shall be stored under cover, protected from direct sunlight and have good
ventilation.

6.1.2.1 Damaged Pipe Materials

After the pipes materials have been placed on the ROW, they shall be inspected by the representatives
of the Contractor and the Engineer at the same time and any defective pipes shall be rectified or
rejected as directed by the Engineer. The Contractor shall supply new replacement pipe materials in
accordance with the same specification as the rejected items.

6.1.2.2 Placing of the Pipe on Site

Prior to jointing, pipes shall be placed alongside the trench on a relatively smooth, level surface free
of sharp stones, debris or other materials. If such conditions do not exist on site then the pipes shall
be placed on supports that lift them clear of the surrounding ground.

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If they so choose, the contractor may place the pipes on a racking system adjacent to where they are
to be jointed.

6.1.3 Care of Other Materials

Other materials supplied by the Contractor or free issued to them shall be stored in a secure and
sheltered place and such material shall not be placed on the ROW but shall be transported from the
storage area when needed.
The materials shall handled and stored in the correct manner to avoid any damage, deterioration,
adulteration or dispersion of the materials and to avoid any health and safety hazards. When supplied
in containers or other packaging they shall be handled with care and in accordance with the
manufacturer’s instructions in order that the containers and packaging are not damaged. When no
longer required, the containers and packaging shall be disposed of in accordance with the
manufacturer’s recommendations and in a manner approved by the Engineer.
During handling and storage contact with harmful foreign materials shall be carefully avoided and the
Contractor shall strictly comply with Manufacturer's instructions regarding handling and storage.
Particular care shall be taken with volatile materials that are susceptible to change in properties due
to unsuitable storage conditions and these shall be stored in a temperature controlled environment if
required.
For materials liable to corrosion while in storage, the Contractor shall exercise proper care in line with
the manufacturer’s recommendations.
Flammable materials shall be stored in special safe storage locations in accordance with local
regulations issued by the relevant authorities.

7 TRENCHING

7.1 Excavation
The Contractor shall excavate the pipeline trench on the surveyed route as staked and to the design
profile, but they shall not commence excavation operations until the pipeline centreline has been
approved by the Engineer.
The Contractor shall excavate the pipeline trench within the cleared and graded ROW using any
method approved by the Engineer. Care shall be taken to ensure that fresh material recovered from
trenching operations, intended to be used for backfilling over the pipe in the trench or at the berms,
is not mixed with loose debris or with foreign or rejected material, required to be removed from site.

7.2 Normal Cover and Trench Dimensions

Pipeline cover shall be measured from the top of the pipe, after it has been laid in the trench or placed
on the formation level, to the level of the original ground or to the graded surface where such surface
is lower than the original ground level.
The trench width shall be dependent upon the OD of the pipeline, the trench depth and nature of the
ground conditions. Unless approved by the Engineer, the trench width shall be as narrow as is practical
to ensure the effective compaction of the pipe surround and shall be between pipe OD + 300 mm and
pipe OD +600 mm.

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7.3 Minimum Pipe Cover Requirements
The minimum cover to the pipeline shall be 0.9 m or the pipe outside diameter, whichever is greater,
with the following exceptions.
 Main roads, highways and rig road crossings: 1.5 m or the pipe outside diameter, whichever is
greater.
 River, wadi and channel crossings: 2.0 m or as directed by the Engineer
 Service connections may be buried with a cover of no less than 0.6 m in circumstances
approved by the Engineer

7.4 Extra Depth and Clearances

The Contractor shall excavate to additional depth where the pipeline approaches and crosses other
pipelines, sewers, drain pipes, water mains, telephone conduits, and other underground structures to
facilitate the one site bending of the pipe, within limits given in section 10.2 of this specification. The
pipeline shall be laid with at least 0.3 m free clearance under the obstacle or as specified on the
drawings. If greater minimum distances are required by the relevant authorities, those distances shall
be maintained.
Where the pipeline crosses areas whose easements specifically require greater than normal depths of
cover, the trench shall be excavated to extra depth as required, including any necessary "lead in" and
"lead out" lengths to ensure a gradual change of pipeline depth without using vertical bends.
Pipelines laid over the crest of sand dunes shall have a minimum cover of between 2.0 and 3.0 m
depending on the steepness and width of the dune, as directed by the Engineer.

7.5 Crossing and Laying Adjacent to Existing Utilities

Where the pipeline will cross or run adjacent to existing pipelines, cables and other utilities the
Contractor shall apply all methods to ensure the safety and protection of the existing utilities. This
shall include close co-ordination with the relevant authorities throughout the construction works and
particularly during excavation work. Such work shall only be undertaken after receiving the written
approved of the relevant authority and the Engineer.
The design of the crossing shall be such that both the minimum clearance and the minimum depth of
cover as required by the drawings, specifications and the relevant authority is guaranteed. The
minimum clearance required between pipeline and the existing utility shall be 300 mm in all directions
unless the otherwise required by the relevant authority.
The Contractor shall safeguard any buried services in the ROW that are to be crossed with a protection
slab, if required by the relevant authority or by the Engineer.
Details of underground utilities, as available, will generally be indicated on the drawings. However,
the Contractor shall make all practical efforts to obtain plans and full details of all existing and planned
underground services from the relevant authorities and utility operators. The Contractor shall consult
these plans closely at all times whilst undertaking their work, but this shall not relieve them of their
duty to locate and protect all underground utilities and structures, whether shown on the drawings or
not. The Contractor shall use pipe and cable locators and any other necessary means including manual
excavation for locating all utilities and structures along the pipeline route.

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The use of excavation plant close to existing utilities and underground structures may result in their
damage and the Contractor shall only excavate the trench within 2 m of such utilities and structures
manually unless they received the written approval of the Engineer.
Where the pipeline crosses other underground utilities and structures, the Contractor shall first
manually excavate and expose such utilities and structures and clearly record their details and location
on as-built drawings i.e. type, diameter, horizontal and vertical location and angle relative to the new
pipeline. This work shall be completed before mechanical excavation plant is allowed to operate
within 10 m of the utility location shown on the drawings or indicated by utility organisation personnel.
Temporary underpinning, trench sheeting or any other supports and protective devices necessary to
protect existing utilities and structures affected by the pipeline works shall be provided by the
Contractor. The excavation works shall be undertaken in such a way that even under the worst
weather and flooding conditions, the existing pipelines/utilities shall remain stable and not be either
undermined or slide towards the trench.
If, despite all precautions, any damage should occur to any utilities or structures the relevant owner
or authority, together with the Engineer shall immediately be informed by the Contractor and repairs
shall be completed at the Contractor's expense. The repairs shall be completed under the direction
and to the satisfaction of the Engineer and the relevant authority. If The Contractor fails to complete
the repairs within a time agreed upon or to the satisfaction of the relevant authority, the Engineer
reserves the right to have the repairs completed by others at the cost of the Contractor.
The Contractor shall also arrange and provide all permanent protection measures to utilities and
structures which the pipeline crosses, as required by relevant authority and to their satisfaction.
If it is deemed necessary, the Contractor shall, subject to clearance of all the relevant authorities,
arrange to re-route existing utilities that are obstructing the pipeline works. The rerouting design and
arrangements shall be fully approved by the relevant authority and shall be undertaken by an
approved sub-contractor designated by the authority.

7.6 Trenching Across or Along Roads and Tracks

The Contractor shall obtain the written permission of the relevant authorities, before commencing
work and shall ensure that all regulations and requirements of the authority having jurisdiction over
such roads and tracks are complied with.
The minimum depth of cover to be provided at each road crossing shall be indicated in the drawings
and comply with the requirements of this specification and the relevant authorities.
The Contractor shall, in all cases where the trench has been cut across or along roads and tracks
provide detours or temporary bridges etc. As set out in section 5.9 of this specification.
Approved warning signs and barriers shall be placed and maintained while such trenches are open. If
such crossings are open at night, the Contractor shall provide adequate number of warning lights of a
type approved by the Engineer and the relevant authorities.
Wherever deemed necessary by the Engineer, the Contractor shall arrange to complete the trenching,
laying and backfilling of such crossings and to remove the temporary bridging before the end of the
regular work day in order to minimise the hazard to night traffic.

13
7.7 Grading and Finishing of Trench or Formation
The trench or formation shall be cut or made to a grade that shall provide a firm, uniform and
continuous support for the pipe, allowing for any necessary pipe bedding. Bends shall be made in the
pipe at significant changes in the grade of the trench.
The minimum number of vertical bends shall be laid to ensure that the pipe conforms to the general
contour of the ground and to maintain the minimum cover. Where practical, this instead shall be
accomplished by cutting the trench slightly deeper at the crest of ridges and by gradually deepening
the trench in approaches to road and channel crossings.
The bottom of the pipe trench shall be dug as square as practical using mechanical plant and if
required, the Contractor shall trim the bottom and lower sides of the trench by hand to ensure the
bottom of the trench is flat and square with the sides and free of loose rock and other hard lumps of
material. Any soft spots shall be excavated and filled with selected excavated material approved by
the Engineer.

8 BACKFILLING

8.1 General
No backfilling shall be performed until the pipeline is at the proper alignment and depth shown in the
drawings, taking in to account any amendments approved by the Engineer. Before any backfilling is
commenced it shall be the Contractor's responsibility to first secure the approval of the Engineer. If
any backfilling is done without the Engineer’s approval, the Engineer has the right to require removal
of backfill for examination. The cost of such uncovering and re-backfilling shall be borne by the
Contractor.
The backfill shall be maintained by the Contractor against being washed out etc. until the completion
and final acceptance of the work by the Engineer.

8.2 Pipe Bed and Surround

Unless the pipeline is laid in sandy ground conditions free of rock and lumps of large material the
Contractor shall lay a well compacted pipe bed across the width of the trench bottom. The pipe bed
shall have a minimum thickness of 100 mm and be compacted to a minimum modified Proctor
(AASHTO) density of 90% prior to the laying of the pipeline.
After laying of the pipeline the Contractor shall place pipe surround material on both sides of the pipe,
ensuring that no cavities are left between the underside of the pipe and the trench bottom or pipe
bed. The pipe surround material shall be placed in layers of no more than 150 mm thick and
compacted with hand tools across the width of the trench to achieve a minimum Modified Proctor
(AASHTO) density of 90%. The pipe surround shall extend to a minimum of 200 mm above the crown
of the pipe.
Where pipes are laid in good quality ground conditions such as those native soils comprising granular,
sandy or rocky materials, the pipe bed and surround shall comprise clean dry sand free from silty and
foreign materials and particles of larger than 10 mm diameter.
Should the excavated native soil fail to meet the above requirements it shall be graded on site in order
to do so or be replaced with an imported sand or granular material complying with the requirements
of the UK WIS 4-08-02 described in Tables 7.1, 7.2 or 7.3 below.

14
Where pipes are laid in poor quality ground conditions such as those native soils comprising soft or
silty materials, the pipe bed and surround shall comprise an imported granular material complying
with one of the grades given in the UK WIS 4-08-02, which are given in Tables 7.2 and 7.3 below.
Table 7.1 – Grading of sand (fine aggregate)

Sieve Percentage by mass passing BS sieve

size
(mm) Overall Additional limits for grading
Limits
Course Medium Fine
10,00 100 – – –
5.00 89 – 100 – – –
2.36 60 – 100 60 – 100 65 – 100 80 – 100
1.18 30 – 100 30 – 90 45 – 100 70 – 100
0.60 15 – 100 15 – 54 25 – 80 55 – 100
0.30 5 – 70 5 – 40 5 – 48 5 – 70
0.10 0 - 15 – – –

Table 7.2 – Grading of graded aggregate

Sieve Percentage by mass passing BS sieve

size Graded aggregate
(mm)
40 to 5 20 to 5 14 to 5
50,00 100 – –
37.50 90 – 100 100 –
20.00 35 – 70 90 – 100 100
14.00 – – 90 – 100
10.00 10 – 40 30 – 60 50 – 85
5.00 0–5 0 – 10 0 – 10
2.36 – – –

Table 7.3 – Grading of single sized aggregate

Sieve Percentage by mass passing BS sieve

size Single sized aggregate
(mm)
40 20 14 10 5
50,00 100 – – – –
37.50 85 – 100 100 – – –
20.00 0 – 25 85 – 100 100 – –
14.00 – – 85 – 100 100 –

15
 10.00 0–5 0 – 25 0 – 50 85 – 100 100
5.00 – 0–5 0 – 10 0 – 25 45 – 100
2.36 – – – 0–5 0 – 30

Note: Single sized aggregate shall not be used for the pipe bed and surround in conditions where the
native soil comprises of sandy, silty or soft material unless it is wrapped in a geotextile filter fabric to
prevent migration of fine material from the surrounding soil in to the bed and surround
The maximum particle size of the granular material shall not exceed 10% of the pipe outside diameter.
When the grade at which the pipeline laid exceeds 10o trench breakers or clay dams shall be installed
to prevent the migration of bed and surround material due to the flow of water along the trench.

8.3 Geotextile Filter Fabric

Geotextile filter fabric for single size granular pipe bedding and surround shall comply with the
requirements of Table 8.3 below and shall be welded or mechanically bonded ultra violet stabilised
polypropylene fibre mats made from continuous filament.

Table 8.3 – Geotextile filter fabric properties

Property Test Method Required Value
Tensile strength ISO 10319 6kN/m min
Puncture resistance ISO 12236 1000N min
Pore size ISO 12956 120 microns max
Water permeability ISO 11058 50 to 125l/sec/m2
Weight ISO 9864 130g/m2 min

8.4 Selection and Placing of Backfill Materials

Above the bed and surround the main backfill material shall comprise selected excavated material
that shall free of any rock or artificial hard material having a diameter in excess of 150 mm. It shall
also be free of other unsuitable material such as large lumps of clay, construction debris and soft
organic material such as peat or silts with a very high organic content. The Contractor shall remove
and dispose of any backfill material rejected by the Engineer and replace it with suitable material.
Above the pipe bed and surround the backfilling of the trench with selected excavated material shall
take place with the material being placed and compacted in layers of no more than 200 mm. Vibrating
mechanical rollers or other approved vibrating compaction plant shall be used once the depth of fill
above the crown of the pipe exceeds 300 mm. Below this depth only hand tools may be employed.
The compaction shall attain a minimum Modified Proctor (AASHTO) density of 85%.
Except in the cases of pipelines laid beneath metalled roads, the finished surface of the backfilled
trench, after the reinstatement of any topsoil or track surface shall be trimmed to follow the existing
ground contours. Limited quantities of surplus excavated material may however be placed to form a
limited mound over the pipe trench to take account of any settlement that may occur. The height and
width of any such mounding shall be to the approval of the Engineer and any other surplus excavated
material shall be disposed of by the Contractor in accordance with the appropriate local regulations.

16
Any depressions caused by settlement of the trench backfill shall be made good by the Contractor
using fill material approved by the Engineer.

8.5 Backfill and Reinstatement of Trenches in Roads and Tracks

Where the trench has been excavated along or across existing or proposed roads and tracks the main
backfill material shall be thoroughly placed and compacted in compliance with the requirements of
the relevant authority.
In the absence of any relevant authority requirements the material shall be placed and compacted in
accordance with the above requirements, but the minimum degree of compaction shall be a Modified
Proctor (AASHTO) density of 95%. This requirement shall also apply along the route of proposed roads
and tracks which have not yet been constructed.
Any underground drainage interrupted by the trenching operation shall be carefully restored and
protected and any damaged portions replaced. In such locations, backfilling with mechanical
equipment shall be prohibited where, in the opinion of the Engineer, damage could result to any
service or structure in the vicinity.
In the case of unmetalled roads and tracks the capping of the filled trench shall comply with the
requirements of the relevant authority. If there are no such requirements then the track shall be
reinstated to its original state or shall be capped with a 200 mm thick cementatious graded granular
material, as directed by the Engineer.
In the case of metalled roads the surface shall be reinstated in accordance with the requirements of
the relevant authority. If there are no such requirements then the track shall be reinstated to its
original state or as directed by the Engineer.

9 NON-DISRUPTIVE CROSSINGS

9.1 General
Non-disruptive crossings shall be defined as the crossing of roads, tracks, railway lines, channels,
existing infrastructure and utilities that is achieved without the excavation of a trench and the
conventional laying of a pipeline.

9.2 Construction Methods

As and when directed in the contract drawings, crossings of major roads and other infrastructure shall
be undertaken using non-disruptive techniques. In most cases this shall entail the use of horizontal
directional drilling techniques, though alternative methods such as thrust boring and micro-tunnelling
may be proposed by the Contractor.
The Contractor’s proposed methodology must fully comply with the requirements of the relevant
authorities and the Contractor shall gain the approval of all those authorities together with their
written permission to proceed with the works, prior to requesting the Engineer’s final approval to
commence work.
Should any of the operations fail to install a pipeline the bore or casing shall be filled in accordance
with the requirements of the relevant authorities prior to being plugged with concrete at either end.
If the relevant authorities have no requirements in this regard, the bore or casing shall be completely
filled with a grout or similar high flow cementitious material that shall prevent its collapse or
settlement at a future date. The details of such arrangements shall be to the approval of the Engineer.

17
10 PE100 PIPE LAYING

10.1 General
Laying of the pipe and making of connections shall be undertaken in a dry trench.
During pipe laying operations the ends of the pipe shall remain sealed by end closures, until
immediately prior to jointing.
Pipe handling shall be in accordance with the requirements of Section 6 above and the pipe
manufacturer’s recommendations. Exposed PE pipe shall be properly supported and protected from
mechanical damage.
The induction of stresses in the pipe or in joints during installation shall be avoided where possible
and the following precautions shall be taken:
 Ensure that the pipe is not damaged by coming in to contact with sharp or abrasive materials
during handling, jointing or installation and that it is regularly supported along its length.
 When pipes are pulled as part of the jointing or laying process care shall be taken to ensure that
the drag force does not exceeding the allowable force as specified by the pipe manufacturer.
Pipes shall only be pulled when they are supported by roller assemblies and are free of the
ground surface and other obstructions in order to ensure that they are not damaged during the
process.
 The contractor shall comply with the minimum allowable bending radii specified in section 10.2
of this specification.
 Ensure that the trench is in compliance with the requirements of section 7 of this specification
and that proper bed and surround material are used.
 Whilst placing the bed and surround material ensure that no stones or other hard materials
impinge on the surface of the pipe.
 If the pipe is laid in a sleeve, ensure that the sleeve ends are fitted in such way that no stress or
cutting effect can be transmitted to the PE carrier pipe.

10.2 Minimum Allowable Bending Radius

PE100 pipes may be bent or curved on site down to a minimum radius as recommended by the
manufacturer. In the event of the manufacturer providing no recommendation, the minimum bend
radius shall not be less than 25 times the pipe OD, Where there are space restrictions the bend radius
may be reduced down to 20 times the pipe OD, but only with the written permission of the Engineer.
No electro-fusion or mechanical joints should be incorporated in the sections of pipework which are
to be bent. Instead a formed bend or elbow should be welded in the pipeline in order to prevent
excessive stress.

11 PIPE JOINTING

11.1 General
The Contractor shall abide by the following guidelines with regards to jointing PE100 pipes and
fittings unless otherwise approved by the Engineer.

18
 PE100 pipes and fittings of 90 mm OD and above shall joined by butt fusion whenever possible.
 PE100 Pipes and fittings of less than 90 mm OD shall be joined together using electro-fusion
couplings and fittings.
 Electro-fusion fittings may also be used to undertake repairs and install off-takes or connections
on existing pipelines. They may also be used for the joining together of pipe strings where it is
not practical to use a butt fusion welding machine.
 To join PE pipes to metal pipes and fittings such as valves, restrained mechanical transition
fittings and stub flanges shall be used.
 Restrained mechanical fittings may, with the permission of the Engineer, also be used to join
together service connection pipework

11.2 Pipe Jointing Personnel

The Contractor shall employ the services of the pipe manufacturer, a specialist sub-contractor or a
specialist team within their own organisation to undertake the jointing of all PE100 pressure pipes and
fittings.
All team members that undertake the butt fusion or electro-fusion of pipes and fittings shall have been
fully trained in theoretical and practical aspects of pipe welding and the use of appropriate equipment.
They shall have undergone an examination and be certified as PE100 pipe welders in accordance with
an approved international standard. The examination and certification shall be undertaken by a
competent authority approved by the Engineer.

11.3 Method Statement

A detailed method statement for PE pipe jointing shall be prepared by the Contractor and submitted
to the Engineer for approval. The method statement shall include details of which equipment shall be
used and how the work will be performed to ensure compliance with the recommendations of the
pipe manufacturer and of this specification.
It shall include, but not be limited to:
 Details of the equipment to be employed by the Contractor, together with procedures for its
operation, maintenance, periodic inspection and testing.
 Details of the experience and certification of the pipe and fitting jointers that shall be employed
by the Contractor.
 Procedures for joint preparation, indicating method and degree of cutting, cleaning, drying,
scraping, alignment, support, etc. of the pipe ends to be joined.
 Jointing procedures, specifying the equipment and tools to be employed, together with all
relevant parameters such as voltage, temperature, pressure, heating time and cooling down
time and the means by which jointing operations shall be controlled.
 Inspection and testing procedures together with proposals for the independent and on site
inspection and testing on welds on a regular basis.
 QA/QC procedures
 All safety precautions and procedures.

19
11.4 Electro-fusion Jointing
Only barcode labelled electro-fusion fittings incorporating fusion indicators and complying with the
requirements of ISO4427, Part 3 shall be used.
The equipment used for electro-fusion jointing of pipes and fittings shall comply with the
requirements of ISO 12176 Part 2. It shall incorporate an automatic control unit with data input
through the use of a bar code reader pen and a data retrieval facility to allow historical fusion data to
be read on the unit’s screen and to be exported to an external computer or memory stick.
The electro-fusion control box shall deliver the correct fusion parameters to the electro-fusion fitting.
The power generator shall provide the power requirements of the control box, taking into account the
electrical characteristics of the control box.
Positioning tools including suitable alignment clamps shall at all times be used to minimise
misalignment and prevent movement during the fusion and cooling cycle of the joint. A suitable
shelter shall be used in cold, windy, dusty or wet weather conditions.
Prior to commencing the welding process the Contractor shall measure and ensure that the ovality of
the pipe or spigot end is within the limits given in Table 3 of ISO 4427, Part 3.
All pipework shall be cleaned with disposable alcohol impregnated wipes prior to undertaking the pipe
scraping, in order to remove any contamination. Prior to scraping the Contractor shall measure and
mark the area of the pipe or spigot end to be scraped in order to remove the oxidized surface to a
depth between 0.2 and 0.4 mm. The length of the pipe or spigot end to be scraped shall be equivalent
to the insertion depth of the electro-fusion joint plus a distance of between 10 and 20 mm.
Only rotating mechanical scrapers or peelers, which are capable of cutting a continuous strip or ribbon
over the insertion length of the coupler or fitting, shall be used.
Only after preparation and scraping of the pipe end shall the fitting be removed from its packaging
and immediately inserted over the pipe end.
Each pipe or spigot end shall penetrate completely its relevant part of the electro-fusion socket.
Alignment clamps shall not be removed before the appropriate cooling time has elapsed. Abnormal
displacement of the electric wire coils shall not occur. This shall be checked prior to commencement
of the fusion process.

11.5 Electro-fusion Joint Inspection

All completed electro-fusion joints shall be inspected in accordance with the requirements of
Appendix B of EN 12007 Part 2. Should the joint contain any of the faults described in the standard
then the electro-fusion fitting shall be cut out and replaced.
After completion of the fusion process, all fusion indicators shall be checked to ensure that they are
in the position indicated in the Manufacturer's instructions. If any fusion indicators are not in the
required position the electro-fusion fitting shall be cut out and replaced.
The Contractor shall, on a regular basis allow the Engineer to download the historical data relating to
the welds made by the unit through the data retrieval facility.

20
11.6 Butt Fusion Jointing
The equipment used for butt fusion jointing of pipes and fittings shall comply with the requirements
of ISO 12176 Part 1. It shall incorporate a control unit that shall comply with the type A requirements
of table B.2 of ISO 12176, Part 1 and the following points.
 Automatically preset the fusion jointing parameters based on the pipe dimensions, material
type and fusion jointing procedure
 Automatically control and monitor the fusion jointing process
 Comply with the requirements of Annex A of ISO 12176, Part 1
 Assign a unique joint number to each joint and have a data retrieval facility to allow historical
fusion parameters to be read on the unit’s screen and to be exported to an external computer or
memory stick
The butt fusion jointing procedures shall comply with the requirements of ISO 21307. The Contractor
shall generally follow the single low pressure fusion jointing procedure described in section 5.1 of ISO
21307.
In the case of pipes having a wall thickness in excess of 20 mm the Contractor may propose to instead
follow the single high pressure fusion jointing procedure described in section 5.2 of ISO 21307.
Only pipes and fittings of the same size, SDR and material are to be butt fusion jointed.
A dummy joint shall be made at the start of each welding session using pipe off cuts of the same size,
material and SDR as the pipe being installed. The normal trimming, bead up and full heat soak cycles
will be adhered to.
If the pipe size is changed during the day, if the heater plate is allowed to cool below 180°C or if
maintenance of the butt fusion equipment is carried out then a new dummy weld shall be performed.

11.7 Butt Fusion Joint Inspection

All butt fusion joints shall be inspected in accordance with the requirements of Appendix B of EN 12007
Part 2. Should the joint contain any of the faults described in the standard then the joint shall be cut
out and replaced. The inspection shall include the following points:
 The gap between the two single beads shall not be below the fusion surface.
 The displacement between the fused pipes must not exceed 10% of the pipe wall thickness.
 The difference between two single bead widths shall not exceed 10% of the double bead width.
 The weld beads shall be free from all contamination and have a smooth even surface with no
evidence of distortion, holes or bubbles
 At the direction of the Engineer external beads shall be removed with an approved tool and
inspected for contamination and defects. They shall also undergo bend back testing. Beads should
be solid and rounded with a broad root as hollow beads with thin root and curled appearance
can be indicative of excessive pressure or no heat soak.
 Each removed bead shall be numbered with its corresponding joint number clearly displayed and
removed beads shall be retained for inspection by the Engineer.

21
 The width of each external bead width shall be measured using bead gauges and the width of
the bead shall be within the range given by the pipe and / or welding equipment manufacturer.
 No signs of damage (such as scratches or deep impressions caused by clamps) shall be visible on
either side of the joint.
 Any joints the do not comply with the above requirements shall be cut out and a new joint
made; the failed joint shall be handed over to the Engineer.
 Records of all tests and inspections shall be maintained by the Contractor and made available
for review and approval by the Engineer.

11.8 Testing of Fusion Joints

A minimum, 1 % of all butt fusion joints shall be cut out and destructively tested under laboratory
conditions in accordance with ISO 13953 by an approved testing organisation. The joints to be tested
shall be selected by the Engineer immediately upon completion of the welding process, whereupon
they shall be cut out and delivered for testing.
A minimum of 1 % of all electro-fusion fittings shall be cut out and destructively tested under
laboratory conditions in accordance with ISO 13954 by an approved testing organisation. The fittings
to be tested shall be selected by the Engineer immediately upon completion of the welding process,
whereupon they shall be cut out and delivered for testing. They shall comprise at least 1 of each type
of electro-fusion fitting even if this requires more than 1 % of all electro-fusion fittings to be tested.
Please note that the test requirement is for one fitting of each type i.e. bend, coupling, tapping saddle,
tee etc. not one of each size and type.
All costs associated with the testing, together with any consequent rectification of faults and retesting
shall be borne by the contractor.

12 TYING-IN

12.1 Joining Unconnected Sections

Where sections of the line are to be tied-in after being laid and filled in the trench the length of pipeline
left un-backfilled shall be kept to a minimum, but shall be sufficient to allow some flexibility in the
uncovered pipe and to facilitate the tying-in process.
Tie-in joints in restrained sections of the line shall be made when the ambient temperature is at the
daytime minimum, as far as is practical, to avoid strain in the pipe. Under no circumstances shall the
line be left in tension after the completion of a tie-in connection.
Bell holes made in the trench bottom to facilitate electro-fusion or mechanical jointing shall provide
adequate clearance to enable the jointer to undertake their work without any restrictions.

12.2 Tie-ins after Hydro-testing

Tie-ins after hydro-testing shall be kept to a minimum and will be permitted only where approved by
the Engineer.
The Contractor shall ensure prior to hydrostatic testing that sufficient length of pipe (overlap) is
available to facilitate tying-in.

22
13 RESTORATION OF THE CONSTRUCTION RIGHT-OF-WAY

13.1 General
After completion of backfilling operations, the construction Right Of Way (ROW) and any other area
affected or used in connection with the pipeline construction shall be restored to its original contour
and condition to the approval of the Engineer and to the satisfaction of the relevant authority.
Any surplus excavated materials, defective materials from the construction of the pipeline, refuse and
unusable spoil materials shall be collected and disposed of by the Contractor to an approved site.
Any loose rock scattered over the ROW or adjacent property shall be collected and disposed of by the
Contractor to an approved site.
The construction ROW shall be graded smooth and any topsoil removed shall be reinstated in its
original location with utmost care and the land restored to its original condition.
Terraces, drainages or gutters, whether earth or masonry, damaged or destroyed by the construction
operations shall be reinstated to their original condition.
All fences cut or damaged shall be reinstated by installing, if necessary, new sections of fencing equal
to or better than the sections cut or damaged. Temporary gates shall be removed and replaced by
new fence sections to the satisfaction of the Engineer and owner.

13.2 Progress of ROW Restoration

Restoration of the ROW shall not be left incomplete more than one kilometre behind completion of
backfilling except with the approval of the Engineer. The Engineer may also suspend, without any
compensation, the Contractor's operations except for backfilling and restoration works, when the
restoration work is left incomplete beyond the limit given above.

13.3 Pipeline Markers

The Contractor shall provide suitable pipeline route markers at regular spacing in compliance with the
specification, subject to the Engineer’s approval. They shall also be installed at each side of all road
and major track crossings, other utility crossings, at changes in horizontal direction and at all other
significant locations.

13.4 Equipment Nameplates

The Contractor shall provide all permanent equipment with nameplates, the contents of which shall
be submitted to the Engineer for approval before the plates are manufactured.

14 DETECTABLE WARNING TAPES

The Contractor shall furnish and place an approved type of detectable warning tape during backfilling
work over all pipelines and ducts installed by the Contractor. Suitable warning tapes shall also be
installed over any existing pipeline or other utility uncovered by the Contractor whilst undertaking
their work. Warning tapes shall be placed in compacted backfill material, approximately 300mm above
the crown of the pipeline, on top of the concrete protection slabs or as directed by the Engineer.
The tapes to be placed above water pipelines and ducts carrying water pipelines shall comply with the
requirements of EN 12613 and be a minimum of 150 mm wide. They shall comprise a blue coloured
printed plastic top layer with either an aluminium layer or twin ‘wavy’ pattern tracer wires

23
encapsulated between two plastic layers, which shall allow the tape to be detected by a cable locating
device.
The ends of the aluminium foil or cables shall be connected to adjacent warning tapes laid above the
pipeline so as to give a continuous detection signal along the length of the pipeline between each
chamber when used in conjunction with a cable detection signal generator.
The tape shall have the warning "CAUTION – WATER PIPELINE BELOW" or similar text approved by the
Engineer, in languages instructed by the Engineer.

15 HYDROSTATIC TESTING

15.1 General
Upon substantial completion of the pipeline or major sections, the line shall be cleaned and
hydrostatically tested to prove integrity of the pipeline section and to detect any leakage prior to
commissioning. Testing shall be performed in accordance with the Finnish Standard SFS 3115:E and
the procedure described below. The Contractor shall supply all necessary fittings, equipment and
facilities required to undertake the testing.

15.2 Method Statement

The Contractor shall prepare a detailed Method Statement for the pressure test that shall follow the
procedure described below and be subject to the approval of the Engineer.

15.3 Outline Test Procedure

Seal the pipeline. Fix all blank flanges. Remove air valves. Remove all on line equipment that may be
damaged by high pressure.
Only test against blank flanges, do not attempt to test against closed valves.
Cover the pipe with sufficient backfill to protect it from direct sunlight, leaving joints exposed where
practical. If backfilling is not practicable schedule the tests for early morning or evening.
Fill the pipeline from the lowest point. Bleed the air from all high points and flange points where it is
possible and tighten once water begins to spill.
When the line is full, close off the filling valve and check all flanges and the small diameter test
pipework for leaks.
Phase 1
Commence raising the pressure at the filling point to the operating pressure or a pressure of 5 bar,
whichever is higher. Hold this pressure for a period of 2 hours and add water whenever the pressure
drops by 0.2 bar in order to maintain a steady pressure, whilst visually inspect the pipe length for
leakage.
Phase 2
After two hours raise the pressure to 1.3 times the operating pressure or 6.5 bar, whichever is higher,
as quickly as is practical. Again maintain this pressure for two hours by adding water whenever the
pressure drops by 0.2 bar.
Visually inspect the pipe length for leakage.

24
Phase 3
At the end of the second two hours release the pressure back down to the phase I level i.e. the
operating pressure or 5 bar, within a period of no more than 30 minutes and as quickly as is practical,
in a controlled manner.
Phase 3 – Case 1
If after one hour the pressure in the pipelines remains at or above the operational pressure, the test
is considered to be completed with the pipeline passing the hydrostatic test.
Phase 3 – Case 2
If after one hour the pressure in the pipeline has fallen below the operational pressure, water shall be
added to raise the pressure back to the operating pressure level, having first noted the low pressure
before adding any water.
Phase 3 – Case 2
Measure the added water by draining it off into a measuring cylinder. (i.e. reduce pressure to the
previously recorded low value and save the water bled off). The measured quantity is then compared
against the allowable quantity to determine if the pipeline passes the hydrostatic pressure test.

Figure 1 Graphical Representation of the Hydrostatic Test Process

Case 1 – Pipeline passes test without adding any make up water

25
Figure 2 Graphical Representation of the Hydrostatic Test Process
Case 2 – Water to be added to determine if the pipeline passes or fails

15.4 Test Result

If during Phase 3 the pressure within the pipeline remains at or above the operational pressure of the
pipeline for a period of at least one hour, the pipeline is considered to have passed the hydrostatic
test.
If water needs to be added the pipeline is considered to have passed the hydrostatic test if the quantity
of water added in terms of litres of water per km of pipeline length per hour of the phase 3 period is
less than that given in the following expression and in Figure 3.
Q ≤ Di/50 – 1 (litres / km/ hour)
Q = added water in litres.
Di = internal diameter for the pipeline in mm.

26
Figure 3. Hydrostatic Test – Allowable Quantities of ‘Make Up’ Water

Hydrostatic Test
Pass

15.5 Notes on Test Equipment

The pressure gauge shall be calibrated, certified and to accurate to 0.1 bar. It shall be connected to
the feed pipework.
The small diameter test pipework shall include a bleed valve at upper end of the pipeline and at all
high points together with feed pipework and valve at the lower end of the pipeline. The feed pipework
shall include a means of draining off the water in to a measuring cylinder that shall have a capacity of
at least 2 litres capacity, graduated to 100 mls.
The Contractor shall also have a thermometer for air and water temperature measurement.

15.6 Differences in elevation

Care should be taken not to over pressure the lower end of the system during testing. Gauges should
always be placed at the lower end of the length under test. As far as possible the difference between
the lower and upper end should be kept to one bar. It is recognized that this may not always be
possible when longer lengths are being tested, or where the slope of the pipeline makes it impractical.

15.7 Test pressures at elevated temperature

Where the phase II pressure is within the pressure rating of the pipe and test temperatures are less
than 30 OC no adjustment of test pressure is necessary.

When ambient temperatures at the time of test are over 30 OC or higher and the test pressures exceed
the pressure rating of the pipe (after being derated in accordance with Annex A of ISO 4427-1) then it
is necessary to modify the test pressure according to the table below or as agreed with the pipe
manufacturer.

Test Temp. (OC) 30 35 40 45 50 55 60

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 Multiplier 0.9 0.85 0.8 0.75 0.7 0.65 0.6

15.8 Additional Notes

Care should be taken that any mechanical elements on the system are protected from elevated
pressure or completely removed from the pipeline.

Do not subject the line to prolonged over-pressure. Always aim to complete the procedure within
one working day.

During the summer make sure that the pipe is not subject to direct sunlight during testing.

During pressure testing pay full attention to the HSE aspects of the procedure. In particular keep
the general public away from high pressure test areas.

The test equipment must be capable of pressurizing the test length within a reasonable time. If the
procedure becomes protracted (beyond one working day) the test length may be modified or
reviewed. Extremely long test lengths may be subject to special procedures.

16 DISINFECTION AND FLUSHING OF WATER PIPELINE

16.1 General
All water lines shall be disinfected by The Contractor to the satisfaction of the Engineer.

16.2 Method Statement

The Contractor shall prepare a detailed method statement for disinfection. It shall describe in detail
how the Contractor proposes to perform the various disinfection activities to ensure compliance with
the requirements as set out in this specification and applicable standards, together with the
requirements of the relevant authorities.

16.3 Disinfection and Flushing

After completion of the hydrostatic test and before the pipeline is taken over by the client and placed
in service it shall be disinfected and flushed as per AWWA C651 or as directed by the Engineer.
One (1) week before the Contractor intends to undertake disinfecting/flushing of all or part of the
pipelines, the Contractor shall submit a detailed proposal for the work showing the quantity of water
required. This quantity of water may be obtained by the Contractor from the nearest available source
approved by the Engineer.
The chlorine dose shall be obtained from a sodium hypochlorite solution or other suitable solution to
be approved by the Engineer. Chlorine Dioxide shall not be used. Samples taken from the pipeline
during disinfection at locations directed by the Engineer shall be checked by a suitable comparator in
order to ensure that the sterilising liquid is present throughout the system and at sufficient
concentration.
Sodium Hypochlorite shall not be added directly to the pipe and the free chlorine concentration shall
not exceed 25 mg/l.
At the end of the 24 hour period at operating pressure the chlorine concentration shall be checked. If
there is less than 1 mg/l of free available chlorine in the water, more sodium hypochlorite solution

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shall be introduced and left for a further 24 hour period after which the free available chlorine
concentration shall be checked again. This procedure shall be repeated as necessary until the available
free chlorine taken after 24 hours exceeds 1 mg/l for all samples taken from the length of pipeline
under test. If the concentration of free available chlorine exceeds 5 mg/l at any point the after 48
hours the pipeline shall be flushed out until the concentration falls below this level.
After all testing and disinfection has been completed and the pipeline is ready for handing over in all
other respects including the installation of connections where appropriate, the new pipeline shall be
flushed out with potable water from the existing mains to which the new pipeline or network is or will
be connected. Flushing entry and exit points shall be designed to allow a minimum of 1.0m/s water
velocity in the main pipeline to remove any sand or other debris. The quantity of flushing water shall
be calculated as the equivalent to 3 times the volume of the pipeline to be flushed unless directed
otherwise.
It shall be a condition that the water in the existing network at the point of extraction shall register a
minimum of 0.4 mg/l of free available chlorine when tested with a site comparator prior to any
approval being given to commence flushing. If a reading of less than this is obtained the Engineer shall
be informed and the Contractor instructed accordingly.
Once flushed, the water in the new pipelines shall be allowed to stand for a further 24 hours. Samples
shall then be taken at locations instructed by the Engineer and immediately submitted for chemical
and bacteriological testing at approved laboratories. If available, chemical and bacteriological tests
shall normally be undertaken at the End Users laboratory and a charge may be made for testing. All
charges for water sample testing shall be paid by the Contractor.

16.4 Acceptance Criteria for Disinfection

The pipeline shall not be considered acceptable until faecal coliforms are undetectable in a 100 ml
sample, the bacterial count is within approved limits, the recorded total chlorine content is a minimum
of 0.2 mg/l and the pH is within acceptable limits i.e. between 7.0 and 9.0 unless otherwise instructed
by the Engineer.
If the tests show that a satisfactory drinking water standard has not been achieved, the Contractor
shall repeat the disinfection and flushing process, all at their own expense, until these requirements
are met.
The Contractor is responsible for making himself fully aware of the statutory requirements for
achieving acceptance of bacteriological and chemical standards of the water in the pipelines under
construction.
Flushing water shall be discharged via temporary discharge lines to the surrounding open areas, into
the existing storm water system or in to water courses, as directed by the relevant authorities. Before
being discharged the flushing water shall pass through a baffled tank or similar equipment that shall
be used to de-chlorinate the water.
All other materials, equipment and labour required for the disinfection, flushing operation and
discharge of water shall also be furnished by the Contractor and included in their costs.

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17 CONNECTION TO EXISTING WATER PIPELINES AND SERVICES
After successful completion of hydrostatic, chemical and bacteriological tests the Contractor may
apply for connection to existing pipelines, in advance of preparing the new pipeline or network for
handing over to the End User.
At least two weeks should be allowed for the application to be processed. The Contractor shall follow
strictly the timings and shutdown periods allowed by the End User for the means of connecting to the
existing system. A shutdown application shall also be completed by the Contractor and submitted to
the Engineer and End User if an existing pipeline needs to be shut down in order to make any
connection. Copies of the hydrostatic test results, together with the chemical and bacteriological test
certificates shall be attached to the application form. Connection works shall only proceed once the
End User, in response to the application, has issued a permit to work covering a particular connection.
The Contractor shall submit a detailed method statement setting out the means by which the
connection is to be made, together with highlighting what actions they believe will need to be
undertaken by the End User’s operational staff. The method statement shall identify the steps by
which the Contractor is going to minimise the contamination of the work area and disinfect all
pipework that shall be affected by the connection works.
The Contractor shall prepare all labour, plant and equipment well in advance of the proposed
shutdown date and shall make advance preparations at the site of the connection so as to minimise
the amount of work required during the limited period of shutdown allowed.
No cutting of existing pipework shall be allowed until representatives of both the Engineer and the
End User have officially given their authority for the work to commence. This shall only happen once
the End User’s operational staff have completed their work necessary to isolate the pipeline section
to which the Contractor is to connect.
After the successful completion of the connection works and if agreed by the Engineer and the End
User’s operational staff, the network shall be re-pressurise and brought back in to operation. If a valve
is installed at the subject connection it shall be maintained in a closed position and shall only be
opened for specific flushing requirements at the instruction of the Engineer.

18 PIPELINE COMMISSIONING
Unless otherwise approved by the Engineer the Contractor shall commission the pipelines only after
all hydrostatic pressure testing, disinfection, flushing and connections have been completed. The
Contractor shall prepare a detailed method statement describing the commissioning activities for
each section of the pipeline and these shall be subject to the Engineer’s approval. Once a method
statement has been approved, any change in procedure shall be subject to written approval of the
Engineer.

19 QUALITY ASSURANCE/QUALITY CONTROL

A copy of the Contractor's QA/QC procedures shall be submitted to the Engineer for approval prior to
commencement of works on site. If the Contractor's is ISO 9001:2000 certified, then only a copy of
the ISO certificate is required.
The Contractor shall identify in documents to its manufacturers, suppliers, vendors and
subcontractors all applicable QA/QC requirements imposed by the Engineer and shall ensure

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compliance. On request, the Contractor shall provide objective evidence of their QA/QC surveillance
at all levels of their operation.

20 CONSTRUCTION RECORDS

20.1 General
The Contractor shall submit regular daily, weekly and monthly reports together with a project
completion report. The contents of these different reports shall, as a minimum, include the following
items:

20.2 Brief Daily Reports

 Daily progress and jointing records, test results and details of any repairs
 Actual weather conditions
 Application for variations, if any
 The next day’s working programme
 Details of any accidents or damages
 Activities or materials required from the Engineer or End User at short notice
 Material Receipts

20.3 Detailed Weekly Reports

 Materials taken over by the Contractor together with details of defects, damage and repairs
 List of outstanding activities required by the Engineer or End User
 Required approvals from the Engineer and other parties
 Summary of progress to date, over the last week and planned progress in the coming week
 Summary of the Contractor’s personnel, equipment and plant on site during the last week
 Details of any accidents or damage to property that occurred in the last week
 Details of permissions, permits, approvals and releases received in the last week
 Materials required to be issued by the Engineer or project owner in the coming week

20.4 Detailed Monthly Reports

In addition to the regular monthly reports required by the contract the Contractor shall provide the
Engineer detailing the progress of the pipeline works together with documents including but not
limited to:
 Progress to date, over the last month and planned progress in the coming month
 Plans summarising the progress of the construction works and testing and commissioning of the
pipelines
 Numbers and details of contractor’s personnel, equipment and plant
 Up to date list of contact details for key of personnel such as of management, medical and
safety staff

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 Any pipe welder certificates not previously submitted
 Monthly safety report including details of any accidents or damages
 List of site instructions and other project related correspondence issued by the Engineer
together with their revision, date of issue and approval status
 Up to date list of confirmed Site Instructions issued by the Engineer
 List of approved Vendors and Subcontractors and a brief description of the materials they are
supplying or work that they are undertaking.
 List of equipment calibration and safe working certification submitted by the Contractor
together with their date of submission, status and date of expiry
 List of permits and approvals requested and received by the Contractor together with their
revision, dates of submission and approval together with their status
 Minutes of meetings with the Engineer and other relevant organisations over the last month
together with comments, if any
 List of material certificates submitted by the Contractor, together with their revision, date of
submission and approval status
 Receipts for materials received on site over the last month.
 List of drawings submitted by the Contractor, together with their revision, date of submission
and approval status
 List of method statements submitted by the Contractor, together with their revision, date of
submission and approval status
 List of calculations and other technical submissions submitted by the Contractor, together with
their revision, date of submission and approval status
 List of test reports submitted by the Contractor, together with their result, date of submission
and approval status
 List of current ‘as-built’ drawings submitted by the Contractor, together with their revision, date
of submission and approval status
 List of any other submissions made by the Contractor or issues that require action by the
Engineer and / or the project owner, their date of submission and status
 Project progress photographs

20.5 Completion Report

20.5.1 General
The pipeline completion report shall comprise the final version of the information given in the
monthly progress reports together with the following

 Details of all materials purchased by or supplied to the Contractor during the project together
with details of how these were consumed eg. incorporated in the works, disposed of as scrap
material, retained by the contractor and handed over

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 Final as-built drawings
 Operation and maintenance manuals
 Detailed assembly drawings for all with keyed parts listed for each item of equipment
 Two-year recommended spare parts list for all equipment

20.5.2 As-Built Drawings

The Contractor shall prepare and submit final 'as built' drawings within 3 months of the substantial
completion of the project. These shall include vendor drawings together with the following drawings,
as applicable:
 Overall route maps together with detailed plan and profile drawings
 Any changes in pipeline material, wall thickness, pressure rating and bedding material
 Location and details of valves and associated chambers etc.
 Location and details of other buried services
 Location and details of all crossings
 Location and type of any weighting or anchoring
 Location and type of markers
 Location of ROW and of pipeline with respect to ROW
 Details of geotechnical conditions along the pipeline route
 Details of any embankments, plantations and protection works etc.
The drawings shall be provided in both hard and soft copy formats in the quantities given in the
specification or contract documents. The drawings shall be submitted in accordance with the End
User’s standard format and shall be compatible with the End User’s CAD and GIS system requirements.

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