Office of the Executive Engineer, P.H.E.D., District...

Specifications of D.I. pipeline

Office of the Executive Engineer, P.H.E.D., District Rural Division-IInd, Bikaner

Tender Notice No. : 15/2015-16

Name of Work : lhekUr {ks= fodkl dk;ZØe ds vUrxZr lhekUr {ks= fodkl dk;ZØe ds vUrxZr lhekUr {ks= fodkl dk;ZØe ds vUrxZr lhekUr {ks= fodkl dk;ZØe ds vUrxZr

chdkusj ftys ds xzke uks[kk nS;k esa ikbZi chdkusj ftys ds xzke uks[kk nS;k esa ikbZi chdkusj ftys ds xzke uks[kk nS;k esa ikbZi chdkusj ftys ds xzke uks[kk nS;k esa ikbZi ykbZu fcNkus o tksM+us dk dk;ZAykbZu fcNkus o tksM+us dk dk;ZAykbZu fcNkus o tksM+us dk dk;ZAykbZu fcNkus o tksM+us dk dk;ZA

Cost of Tender Form : Rs. 500.00

Issued to : ---------------------------------------- ---------------------------------------- ---------------------- Estimated Cost : Rs. 23.00 Lacs.

Time allowed for completion : 2 Month

Last date of selling tender : 10.08.2015 upto 3.00 PM

Date & Time of receipt of tender : 12.08.2015 upto 3.00 PM

Date & Time of opening of tender : 12.08.2015 upto 3.30 PM

Earnest Money : Rs. 46,000.00 (2 %)

Executive Engineer PHED, Distt. (R) Dn. II,

Bikaner


"G"-Schedule Name of work : lhekUr {ks= fodkl dk;ZØe ds rgr~ chdkusj ftys dh xzke iapk;r lhekUr {ks= fodkl dk;ZØe ds rgr~ chdkusj ftys dh xzke iapk;r lhekUr {ks= fodkl dk;ZØe ds rgr~ chdkusj ftys dh xzke iapk;r lhekUr {ks= fodkl dk;ZØe ds rgr~ chdkusj ftys dh xzke iapk;r

uks[kk nS;k esa ikbZi ykbZu fcNkus o tksM+us dk dk;ZAuks[kk nS;k esa ikbZi ykbZu fcNkus o tksM+us dk dk;ZAuks[kk nS;k esa ikbZi ykbZu fcNkus o tksM+us dk dk;ZAuks[kk nS;k esa ikbZi ykbZu fcNkus o tksM+us dk dk;ZA

NIT-15/2015-16 SN Particular Unit Qty. Rate Amount

1 Excavating trenches of required width for pipe cables, etc including excavation for sockets and dressing of sides, ramming bottoms, depth upto 1.5 Mtr. including taking out the excavated soil and then returning the soil as required in layers not exceeding 20 cm. in depth including consolidating each deposited layer by ramming watering etc. and disposing of surplus excavated soil as directed within a lead of 50 mtr. Pipe Cables etc. exceeding 90mm dia but not exceeding 315mm dia

Mtr. 2100.00 103.00 216300.00

2 Providing, lowering, laying in trenches, aligning, fixing in position and jointing Ductile Iron (DI) ISI marked K-7 grade S&S pipes as per IS:8329-2000 (amended upto date), with internal cement mortar lining for potable water with rubber ring (EPDM/SBR) joints as per IS: 5382-1985 (excluding special accessories) complete including all material, labour, hydraulic testing and commissioning as per Technical Specifications and as per direction of Engineer. 100mm dia DI (K-7)

Mtr. 550.00 905.00 497750.00

3 Providing, laying and jointing of uPVC pipes with rubber ring joints in assorted length with uPVC specials etc. and interconnection with existing / new pipe line as per specification including preparation of bed properly carting to site with all lead, cutting of pipes, sectional testing of pipe line as per BIS specification, submitting completion drawing as per specification (excluding earth work) 225mm dia uPVC CL-4

Mtr. 1550.00 990.00 1534500.00

4 Fabrication, supply of flanged/ plain ended MS pipe made from MS sheet strips of relevant IS specification of approved thickness by welding, lowering, laying, aligning, fixing in position at all level/ depths in trenches complete (excluding flanged jointing wherever required) including all material, labour, testing and commissioning along with pipe line as per Technical Specifications and as per direction of Engineer. MS pipe specials upto 600mm dia (with minimum 5mm thickness sheet)

Kg. 290.00 86.00 24940.00

Total : 2273490.00

I/We offer………………% Above/Below on "G"-Schedule

Signature of contractor with seal Executive Engineer

PHED Disrict (R) Dn.II Bikaner


Office of the Executive Engineer , P.H.E.D., Distt.(R) Dn.II, Bikaner

Tender Notice No. : 15/2015-16

Name of Work : lhekUr {ks= fodkl dk;ZØe ds vUrxZr chdkusj ftys ds lhekUr {ks= fodkl dk;ZØe ds vUrxZr chdkusj ftys ds lhekUr {ks= fodkl dk;ZØe ds vUrxZr chdkusj ftys ds lhekUr {ks= fodkl dk;ZØe ds vUrxZr chdkusj ftys ds

xzke uks[kk nS;k esa ikbZi ykbZu fcNkus o tksM+us dk dk;ZAxzke uks[kk nS;k esa ikbZi ykbZu fcNkus o tksM+us dk dk;ZAxzke uks[kk nS;k esa ikbZi ykbZu fcNkus o tksM+us dk dk;ZAxzke uks[kk nS;k esa ikbZi ykbZu fcNkus o tksM+us dk dk;ZA

SPECIFICATIONS OF D.I. PIPELINE

1 GENERAL

This part of the specification covers the manufacturing, supply, delivery, lowering, laying, jointing,

internal coating, outer coating, testing and commissioning of DI pipes. Following IS Standards shall

be applicable.

SN Particular IS Standard

1 Specifications for DI Pipes IS 8329-2000

2 DI Fittings and Specials IS 9523-2000

3 Rubber Gasket for DI Pipes IS 5382-1985

4 Laying & Jointing of DI Pipes IS 12288-1987

All diameters indicated in the scope of work and in these specifications for pipes shall be the

nominal diameters for that type of pipe as per respective standards.

All the pipes, valves, DI specials and other pipe appurtenances shall be designed to withstand the

maximum pressures to which it may be subjected to under operation of the project.

2 PREPARATORY WORK OF PIPELINE

2.1 DUCTILE IRON PIPES

Ductile pipes to be used in the contract shall be centrifugally cast (spun) Ductile Iron Lined pipes

suitable for Water and Sewage & conforming to IS 8329 with internal cement mortar lining, and

bituminous outer coating. The manufacturer must have BIS license for manufacturing DI pipes.

Ductile Iron Specials such as bends, Tees, Tapers, tail pieces etc, shall be confirming to the IS 9523:

1980. Unless in case of abnormal site conditions warranting use of MS specials, all specials on DI

pipe line shall be of DI.

The fittings should preferably be procured from the same manufacturer of the pipes. In case they are

not, it will be the responsibility of the manufacturer of the fitting to provide fitting which

commensurate with the supplied DI pipes by the department. The contractor will however be

responsible for the compatibility and quality of the products.

Supplies of rubber gaskets shall be done by the contractor confirming to the relevant specifications.

Contractor shall preferably take them from the approved vendor of the manufacturer of the pipe.

INTERNAL CEMENT MORTAR LINING

The DI pipes shall be supplied with internal cement lining as per IS:8329-2000. The minimum lining

thickness shall be accordingly.


2.1 WORKING LENGTHS AND TOLERANCES

For all purposes, the lengths of the pipes provided by the department shall be the length as defined

in IS: 8329. The pipes will be supplied in standard lengths as per the provisions in the standards IS

8329 to which the manufacturing confirms (IS: 8329). The ends shall be suitably rounded and/or

chamfered ends. Any tolerance in the stipulated lengths will be as per the provision of the standards

to which it has been manufactured (IS: 8329).

The tolerance in diameter, thickness, ovality & permissible deviation from straight line shall be as

per the standards to which the pipe is manufactured (IS 8329)

2.3 STANDARDS FOR RUBBER GASKET

Each pipe of the push on joint variety will also be supplied with a rubber EPDM gasket. The gaskets

will confirm to the provisions of IS 5382:1985. Material of rubber gaskets for push-on mechanical or

flanged joints shall be compatible with working pressure and temperature at which the water is to

be conveyed. Rubber gaskets for use with flanged joints shall conform to IS: 638. While conveying

potable water the gaskets should not deteriorate the quality of water and should not impart any

taste or foul odour.

The gaskets should also be supplied by the manufacturer of the pipes. They should preferably be

manufactured by the manufacturer of the pipes. In case they are not, it will be the responsibility of

the manufacturer of the pipes to have them manufactured from a suitable manufacturer under it’s

own supervision and have it tested at his/sub contractors premises as per the contract. The pipe

manufacturer will however be responsible for the compatibility and quality of the products.

The flanged joints shall confirm to the provisions of IS 8329. The pipe supply will also include one

rubber gaskets for each flange.

2.4 INSPECTION AND TESTING:

The DI Double Flanged pipes supplied by the contractor will be subjected to following tests as per IS

8329 for acceptance:

1. Visual and dimensional check as per IS 8329.

2. Mechanical Tests as per IS 8329.

3. Hydrostatic Test as per IS 8329.

4. Any other tests required as per the provisions to which the supplied pipe confirms

i.e (IS 8329 )

5. The test reports for the rubber gaskets shall be as per acceptance tests of the IS

5382 .

The sampling method for testing shall be as per the provisions of the standards to which they are

manufactured.

2.5 Marking

All pipes will be marked as per provisions of IS 8329 and subjected to the following minimum

requirements:

1. Manufacturer name/ stamp

2. Nominal diameter


3. Class reference

4. Manufacturing standards to which the pipe confirms (IS: 8329) & BIS Licence.

5. Mark of the pre-dispatch inspecting authority

6. A white ring line showing length of insertion at spigot end

2.6 PACKING AND TRANSPORT:

The pipes should be preferably transported by road from the factory and stored as per the

manufacturer specifications to protect damage.

2.7 Pipe Laying - General

2.7.1 Pipe shall be laid below ground unless specified otherwise, the pipeline shall be buried with

minimum cover of 1.0 meters at top, as shown on drawings. No material shall be erected

unless it has been previously passed by the Engineer.

2.7.2 Pipes laid above ground on pedestals shall in general have minimum clear height of 45 cm

between the pipe invert and ground level.

2.8 Lubricant for ductile iron pipes and specials

2.8.1 General

This section covers the requirements for lubricant for the assembly of Ductile Iron pipes and specials

suitable for Tyton push-in EPDM rubber ring joints

2.8.2 Specifications

The lubricant has to have the following characteristics:

o must have a paste like consistency and be ready for use

o has to adhere to wet and dry surfaces of DI pipes and rubber rings

o to be applied in hot and cold weather; ambient temperature 0 - 50 °C, temperature of exposed

pipes up to 70 °C

o must be non toxic

o must be water soluble

o must not affect the properties of the drinking water carried in the pipes

o must not have an objectionable odour

o has to inhibit bacterial growth

o must not be harmful to the skin

o must have a shelf live not less than 2 years

2.8.3 Acceptance tests

They shall be conducted in line with the provisions of the IS 9523

2.9 Specials for Ductile Iron Pipes

GENERAL

This section covers the general requirements for Ductile Iron (DI) fittings suitable for Tyton joints to

be used with Ductile Iron pipes with flanged and Tyton jointing system.

TYPES OF SPECIALS


The following types of DI fittings shall be manufactured and tested in accordance with IS: 9523 or BS:

4772.

• flanged socket

• flanged spigot

• double socket bends (900, 45

0, 22 1/2

0, 11 1/4

0)

• double socket branch flanged tee

• all socket tee.

• double socket taper.

• All Flanged Tee.

• All Flanged taper.

SUPPLY

All the DI fittings shall be supplied with one rubber ring for each socket. The rubber ring shall

conform to IS: 12820 and IS: 5382 as described in the preceding chapter. Flanged fittings shall be

supplied with one rubber gasket per flange and the required number of nuts and bolts.

2.10 Earth Work for PIPELINE

2.10.1 General

The Contractor shall furnish all tools, plant, instruments, qualified supervisory personnel, labour,

materials, any temporary works, consumables, any and everything necessary, whether or not such

items are specifically stated herein for completion of the work in accordance with the Employer’s

Requirements.

The Contractor shall survey the site before excavation and set out all lines and establish levels for

various works such as grading, basement, foundations, plinth filling, roads, drains, cable trenches,

pipelines etc.

The excavation shall be carried out to correct lines and levels. This shall also include, where required,

proper shoring to maintain excavations and also the furnishing, erecting and maintaining of

substantial barricades around excavated areas and warning lamps at night.

Excavated material shall be dumped in low lying land, regular heaps, bunds, riprap with regular

slopes within the lead specified and leveling the same so as to provide natural drainage and

avoidance of formation of any puddle of water near pipe alignment. Rock/soil excavated shall be

stacked properly as approved by the Engineer in Charge. As a rule, all softer material shall be laid

along the center of heaps, the harder and more weather resisting materials forming the casing on

the sides and the top. Rock shall be stacked separately.

Topsoil shall be stock piled separately for later re-use.

2.10.2 Clearing


The area to be excavated/filled shall be cleared of fences, trees, plants, logs, stumps, bush,

vegetation, rubbish, slush, etc. and other objectionable matter. If any roots or stumps of trees are

encountered during excavation, they shall also be removed. The material so removed shall be

disposed off as approved by the Engineer in Charge. Where earth fill is intended, the area shall be

stripped of all loose/ soft patches, top soil containing objectionable matter/ materials before fill

commences.

2.10.3 Excavation

Excavation shall be taken out to such widths, lengths, depths and profiles as are shown on the

approved L-section or such other lines and grades as may be agreed with the Engineer in Charge.

Rough excavation shall be carried out to a depth of 150mm above the final level. The balance shall

be excavated with special care.

Soft pockets shall be removed below the final level and extra excavation filled up with lean concrete

as approved by the Engineer in Charge. The final excavation should be carried out just prior to laying

the blinding course.

To facilitate the permanent works the Contractor may excavate, and also backfill later, outside the

lines shown on the drawings provided by the Contractor as agreed with the Engineer in Charge.

Should any excavation be taken below the specified elevations, the Contractor shall fill it up with

concrete of the same class as in the foundation resting thereon, up to the required elevation without

any cost to the Department.

All excavations shall be to the minimum dimensions required for safety and ease of working. Prior

approval of the Engineer in Charge shall be obtained by the Contractor in each individual case, for

the method proposed for the excavation, including dimensions, side slopes, dewatering, disposal,

etc. This approval shall not in any way relieve the Contractor of his responsibility for any consequent

loss or damage. The excavation must be carried out in the most expeditious and efficient manner.

Side slopes shall be as steep as will stand safely for the actual soil conditions encountered. Every

precaution shall be taken to prevent slips. Should slips occur, the slipped material shall be removed

and the slope dressed to a modified stable slope.

2.10.4 EXCAVATION FOR LAYING PIPE ALONG THE ROAD

While laying the pipeline below ground along the road side, the contractor shall observe the

following:

The contractor shall not be allowed to take earth from the burrow pits if excavation required to take

additional earth results in side slopes steeper than 1:1 in clay dominating soil and 1:1.5 in case of

silty sand or sandy soils.

If invert of pipe is kept above the existing burrow pit level or part of pipe is above it, the minimum

side slopes of 1:1 in clay dominating soil and 1:1.5 in case of silty sand or sandy soils shall be

provided on the side towards the burrow pit area so as to provide required cover. The side slopes

shall be properly compacted up to 90% of modified Procter density.

If earth is taken for providing required cover to pipe from the burrow pits, the burrow pits shall be so

graded up to the nearest drain, that no impounding of water is possible in burrow pit area.


If the pipeline is laid just near the road section, as far as practical minimum cover of 1.0 m shall be

ensured. Whenever this requirement of cover cannot be ensured, concrete casing of deigned

thickness as per considerations given for design in this chapter shall be provided.

2.11 PIPE LAYING BELOW GROUND

2.11.1 TRENCH EXCAVATION

The earth work shall be carried out as specified above

Before excavating the trench the alignment of pipeline and L-section shall be approved by Engineer-

in-charge. The work of trench excavation should be commensurate with laying and jointing of the

pipeline. It should not be dug in advance for a length greater than 3 days ahead of work of laying and

jointing of pipeline unless and otherwise directed by the Engineer in charge. It is proposed to ensure

the following:-

1. Safety precautions have to be incorporated in the work progress

2. Hindrances to the public have to be minimized

3. The trench shall not be allowed to erode

4. The trench must not be filled with water.

5. The trench must not be refilled before laying of the pipes.

6. The bed for the laying of the pipes has to be prepared according to the L-section

immediately before laying of the pipes.

The trench excavation of pipe line shall be in accordance with IS 12288. Pipe trenches shall be

excavated to the lines and levels shown on the drawings or as directed by the Engineer. The depth of

the excavated trench shall be as given in the drawings or as directed by the Engineer. The width of

the trench at bottom between the faces of sheeting shall be such as to provide 200 mm clearance on

either side of the DI pipe except where rock excavation is involved. No pipe shall be laid in a trench

until the section of trench in which the pipe is to be laid has been approved by the Engineer.

The depth should be sufficient to provide a cover not less than 1000 mm so that the pipe line will

not interfere with the cultivation of land. It may be necessary to increase the depth of pipeline to

avoid land drains or in the vicinity of roads, railways or other crossing. Care should be taken to avoid

the spoil bank causing an accumulation of rain water.

The bottom of the trench shall be trimmed and leveled to permit even bedding of the pipes. It

should be free from all extraneous matter, which may damage the pipe or the pipe coating.

Additional excavation shall be made at the joints of the pipes, so that the pipe is supported along its

entire length.

All excavated material shall be stacked in such a distance from the trench edge that it will not

endanger the work or workmen and it will avoid obstructing footpaths, roads and drive ways.

Hydrants under pressure, surface boxes, fire or other utility controls shall be left unobstructed and

accessible during the construction work. Gutters shall be kept clear or other satisfactory provisions

made for street drainage, and natural water – courses shall not be obstructed.

To protect persons from injury and to avoid damage to property, adequate barricades, construction

signs, torches, red lanterns and guards, as required, shall be placed and maintained during the


progress of the work and until it is safe for traffic to use the roadways. All materials, piles equipment

and pipes which may serve as obstruction to traffic shall be enclosed by fences or barricades and

shall be protected by illuminating proper lights when the visibility is poor.

As far as possible, the pipe line shall be laid below existing services, like water and gas pipes, cables,

cable ducts and drains but not below sewers, which are usually laid at greater depth. Where it is

unavoidable, pipeline should be suitably protected. A minimum clearance of 150 mm shall be

provided between the pipeline and such other services.

Trees, shrubbery fences, poles, and all other property and surface structures shall be protected. Tree

roots shall be cut within a distance of 50 cm from pipe joints in order to prevent roots from entering

them. Temporary support, adequate protection and maintenance of all under ground and surface

structures, drains, sewers and other obstructions encountered in the progress of the work shall be

provided. The structures, which will be disturbed, shall be restored after completion of the work.

Wherever necessary to prevent caving, trench excavations in soils such as sand, gravel and sandy soil

shall be adequately sheeted and braced. Where sheeting and bracing are used, the net trench width

after sheeting shall not be less than that specified above. The sides of the excavation shall be

adequately supported at all times and, except where described as permitted under the Contract,

shall be not battered.

The Engineer in co-operation with the Contractor shall decide about the sheeting / bracing of the

trench according to the soil conditions in a particular stretch and taking into account the safety

requirements of the Contractor’s and Engineer – In – Charge’s staff. Generally, safety measures

against caving have to be provided for trenches with vertical walls if they are deeper than 2.0 m.

2.11.2 Trench Excavation to Commensurate With the Laying Progress

The work of trench excavation should be commensurate with laying and jointing of the pipe line. It

should not be dug in advance for a length greater than 500 m ahead of work of laying and jointing of

pipeline unless other wise defined by the Engineer. The Contractor has to ensure the following:

1. safety protections as mentioned above have to be incorporated in the work process

2. hindrances to be public have to be minimized

3. the trench must not be eroded before the pipes are laid

4. the trench must not be filled with water when the pipes are laid

5. the trench must not be refilled before laying of the pipes.

The bed for the laying of the pipes has to be prepared according to the L-Section immediately before

laying of the pipes.

2.11.3 BEDDING OF THE PIPES:

The DI pipeline shall generally be laid in ordinary sandy soil for which no extra bedding shall be

provided. In such case, while doing the excavation, the bottom of the trench shall be prepared in a

manner so as to match the curvature of the pipe as far as possible subtending an angle of about 120o

at the center of pipe. Wherever the bottom of the trench is of such a nature (i.e. any type of rock /

hard soil/ boulder) which is likely in the opinion of the Engineer-in-Charge to cause damage to the

pipe or coating or an unsuitable material is encountered which cannot support the pipe, the

contractor shall excavate the trench to an additional depth below the required depth and shall refill


to required level with suitable material such as loose soil/ sand, to be approved by the Engineer-in-

Charge. The bedding thickness shall be not less than 15 cm under the barrel of the pipes. The

complete pipe has to be covered and surrounded by the same material as used for bedding so that a

total cover of 30cm above the barrel can be achieved. The excavated hard/dense soil can be refilled

after bedding and covering of the pipe with the loose soil/sand.

The bedding shall be compacted with a light hand rammer. Adding sand during ramming shall make

up any reduction in thickness due to compaction. For the purpose of the bedding under this item

only screened fine sand of grain size not larger than 2mm shall be used. The sand shall be a clean,

uncoated and free form clay lump, injurious amounts of dust, soft particles, organic matter, loam or

other deleterious substances.

If the sand supplied is unclean it shall be washed. In no case shall sand containing more than 3.5 %

by dry volume or 5% by wet volume of clay, loam or silt be accepted. Tests specified for determining

silt in sand and organic impurities as described in IS: 383 shall apply. Sieved and washed sand shall

be stored on the works in such a manner as to prevent intrusion of any foreign matter, including

coarser particles of sand or any clay or metal or chips. Tests as indicated above shall be performed if

called for by the Engineer at the expense of the Contractor.

During the work of providing sand bedding and laying the pipeline over it, loose material from the

sides or edges of the trench shall be prevented from falling inside the trench, by providing shoring

and taking other measures. Also where necessary, trench shall be kept dry by pumping out seepage

water continuously.

2.12.1 STRINGING OF PIPES ALONG THE ALIGNMENT

The pipes shall be laid out properly along the proposed alignment in a manner that they do not

create any significant hindrance to the public and that they are not damaged.

Stringing of the pipes end to end along the working width should be done in such a manner that the

least interference is caused in the land crossed. Gaps should be left at intervals to permit the passing

of equipment across the working area. Pipes shall be laid out that they remain safe where placed

and that no damage can occur to the pipes and the coating until incorporated in the pipeline. If

necessary, pipes shall be wedged to prevent accidental movement. Precautions shall be made to

prevent excessive soil, mud etc. entering the pipe.

Generally, the pipes shall be laid within two weeks from the date of their dispatch from the

manufacturer / store.

2.12.2 LAYING AND JOINTING OF DI PIPES

Pipes should be lowered into the trench with tackle suitable for the weight of pipes. For smaller

sizes, up to 200mm nominal bore, the pipe may be lowered by the use of ropes but for heavier pipes

suitable mechanical equipment have to used.

All construction debris should be cleared from the inside of the pipe either before or just after a

joint is made. This is done by passing a pull-through in the pipe, or by hand, depending on the size of

the pipe. All persons should vacate any section of trench into which the pipe is being lowered.

On gradients of 1:15 or steeper, precautions should be taken to ensure that the spigot of the pipe

being laid does not move into or out of the socket of the laid pipe during the jointing operations. As

soon as the joint assembly has been completed, the pipe should be held firmly in position while the

trench is back filled over the barrel of the pipe.


The designed anchorage shall be provided to resist the thrusts developed by internal pressure at

bends, tees, etc.

Where a pipeline crosses a water course, the design and method of construction should take into

account the characteristics of the water course to ascertain the nature of bed, scour levels,

maximum velocities, high flood levels, seasonal variation, etc. which affect the design and laying of

pipeline. The pipe shall be laid accordingly with adequate protection.

The assembly of the pipes shall be made as recommended by the pipe manufacturer and using the

suitable tools.

The socket and spigot ends of the pipes shall be brushed and cleaned. The chamfered surface and

the end of the spigot end have to be coated with a suitable lubricant recommended by the

manufacturer of the pipes. Oil, petroleum bound oils, grease or other material, which may damage

the rubber gasket, shall not be used as lubricant. The rubber gasket shall be inserted into the

cleaned groove of the socket. It has to be checked for correct positioning.

The two pipes shall be aligned properly in the pipe trench and the spigot end shall be pushed axially

into the socket either manually or with a suitable tool specially designed for the assembly of pipes

and as recommended by the manufacturer. The spigot has to be inserted up to the insertion mark

on the pipe spigot. After insertion, the correct position of the socket has to be tested with a feeler

blade.

Deflection of the pipes –if any- shall be made only after they have fully been assembled. The

deflection shall not exceed 75% of the values indicated by the pipe manufacturer.

2.12.3 FILL, BACKFILLING AND SITE GRADING

Trenches shall be backfilled with approved selected excavated material only after the successful

testing of the pipeline. The tamping around the pipe shall be done by hand or other hand operated

mechanical means. The water content of the soil shall be as near the optimum moisture content as

possible. Filling of the trench shall be carried out simultaneously on both sides of the pipe in such a

manner that unequal pressure does not occur. Each layer shall be consolidated by watering,

ramming, care being taken to avoid damage to the pipeline.

2.12.4 SEQUENCE OF WORKS FOR ENSURING GOOD PIPE LAYING

I. The required fittings, valves and jointing material should be carefully worked out in

beginning. This material should be received in full first of all on site and stored as pre-

directions of manufacturer or as directions given elsewhere in this manual on standards.

II. The pipes should be received on site only after the above fittings, valves and material for

joints have been received and all necessary preparation for laying has been made.

III. The material received should be checked for inspection certification as per contract and

damage during transportation. All damaged should be separated and not used.

IV. The pipes received should be stored strictly as per directions of the manufacturer or as

mentioned elsewhere in this manual in this or standards.

V. The pipes and other material should be again inspected for any damage before use in the

trench.

VI. The fittings and valves should be installed in sequence with the laying of pipes without

leaving any gaps.

VII. It is desirable to lay the pipelines from the end from where it can be connected to the water

source to enable regular flushing of laid pipes.

VIII. The entry of dirt or any foreign material in the pipe should be religiously prevented.

IX. Each joint should be carefully checked for its completeness before covering up.


X. There should be a commensurate progress in trench excavation, laying and jointing of pipes,

fittings, valves etc and testing of laid pipes in sections so as to complete testing of all pipes

laid in quick follow up of completing laying and jointing.

3 JOINTING MATERIAL

Each valve shall be supplied with all necessary joint ring, nuts, bolts and washers for completing the

joints such that it will ensure effective sealing of large orifice even at low pressures.

The weights of floats, in case of air valves, of the same size and type shall not differ by more than

2%. The timber, if used in the manufacture of floats shall be seasoned and those provided in large

orifice shall be ebonite coated. The float provided in high pressure chamber, if manufactured from

seasoned wood, shall be coated with “ethylene propylene Rubber” (EPDM).

4 DOCUMENTATION

MEASUREMENT AND LOGGING

Contractor shall prepare a special logbook containing all the relevant data of individual pipe and pipe

coating, diameter, length, wall thickness, defects, pipe number, lot/batch or materials used for each

pipe. Sampling and testing at site test results at manufacturer's plant(s), tests conducted by

independent agency, damages, repairs, rejects and any other information that Engineer-in-Charge

considers to be relevant and required for all incoming bare pipes and Engineer-in-Charge approved

outgoing coated pipes as applicable. Contractor shall submit this information in the form of a report

at the agreed intervals.

5 FIELD HYDRAULIC TEST

The Field Hydrostatic test pressure shall be as described in following related paras

a) The working pressure and surge pressure shall be calculated for ultimate flow ie

pumping for demand of year 2038.

b) Before start of the testing the pipe shall be kept filled at low pressures for minimum 24

hours to allow absorption of water by lining.

c) Pressure building shall be gradual.

d) The duration of the test shall be 24 hours after attaining full pressure.

e) Allowable leakages shall not exceed 0.1-liter/ mm of pipe diameter per km of pipeline

per day for each 30 m head of pressure applied.

f) Rebuilding of pressure up to the testing pressure shall be done after every fall of 10%

from the testing pressure.

g) Length of a section for testing shall not be more than 1.5 km.

h) Joints shall be kept open during testing. Adequate anchorages shall be provided to avoid

any movement of pipes.

The contractor shall provide and maintain all requisite facilities, instruments, for the field testing of

the material. All pipes, specials, valves and civil works shall be replaced by the contractor free of cost

if damaged during testing. All pipes, specials, valves and Civil Works shall be replaced by the

contractor free of cost if damaged during testing being a SPR contract.


6 FLUSHING AND DISINFECTION OF MAINS

The pipeline shall be disinfected before commissioning for use. After testing the main, it shall be

flushed with water of sufficient velocity to remove all dirt and other foreign materials. When this

process has been completed, disinfections (using liquid chlorine, sodium or calcium hypo-chlorite)

shall be done as per of IS: 5822.

7 TESTING OF THE PIPELINES

7.1 SECTIONAL TESTS

After laying and jointing, the pipeline shall be tested for tightness of barrels and joints, and stability

of thrust blocks in sections approved by the Engineer in Charge. The length of the sections depends

on the topographical conditions. Preferably the pipeline stretches to be tested shall be between two

chambers (air valve, scour valve, bifurcation, and other chamber).

The water required for testing shall be arranged by the contractor himself. The Contractor shall fill

the pipe and compensate the leakage during testing. The Contractor shall provide and maintain all

requisite facilities, instruments, etc. for the field testing of the pipelines. The testing of the pipelines

generally consists in three phases: preparation, pre-test/saturation and test, immediately following

the pre-test. Generally, the following steps are required which shall be monitored and recorded in a

test protocol if required:

a) Complete setting of the thrust blocks.

b) partial backfilling and compaction to hold the pipes in position while leaving the joints

exposed for leakage control

c) opening of all intermediate valves (if any)

d) fixing the end pieces for tests and after temporarily anchoring them against the soil (not

against the preceding pipe stretch)

e) at the lower end with a precision pressure gauge and the connection to the pump for

establishing the test pressure

f) at the higher end with a valve for air outlet

g) If the pressure gauge cannot be installed at the lowest point of the pipeline, an allowance in

the test pressure to be read at the position of the gauge has to be made accordingly

h) Slowly filling the pipe from the lowest point(s).

i) the water for this purpose shall be reasonably clear and free of solids and suspended

matter

j) Complete removal of air through air valves along the line.

k) Closing all air valves and scour valves.

l) Slowly raising the pressure to the test pressure while inspecting the thrust blocks and the

temporary anchoring.

m) Keeping the pipeline under pressure for the duration of the pre-test / saturation of the lining


by adding make-up water to maintain the pressure at the desired test level. Make up water to

be arranged by Contractor himself at his own cost.

n) Start the test by maintaining the test pressure at the desired level by adding more make-up

water; record the water added and the pressure in intervals of 15 minutes at the beginning

and 30 minutes at the end of the test period.

o) Water used for testing should not be carelessly disposed off on land which would ultimately

find its way to trenches.

The field testing pressures for pipelines & duration of test shall be follows:

PIPE MATERIAL TEST PRESSURE TEST

DURATION

DI Pipes (k7 ) 1.5 TIMES THE WORKING PRESSURE OF

PHASE-II (2038) 24 Hours

Field Hydraulic Test

� The pipe line shall be tested for 1.5 times of the working pressure as per design (year

2025) flow.

� Before start of the testing the pipe shall be kept filled at low pressures for minimum 24

hours to allow absorption of water by lining in case testing is allowed after lining by EIC.

� Pressure building shall be gradual.

� The duration of the test shall be 24 hours after attaining full pressure.

� Length of a section for testing shall not be more than 1.5 km.

Acceptance Criteria for DI pipes shall be that the required addition of water to maintain pressure

is not more than

Q = 1 liter per Km per 10 mm of pipe diameter per 30 m test pressure for 24 Hours

The sectional tests shall be accepted if the quantity of water required to be added to maintain

test pressure during test duration of

No section of the pipe work shall be accepted by the Engineer in Charge until all requirements of

the test have been obtained.

When the field test pressure is less than 2/3 the works test pressures the period of test should

be at least 24 hours. The test pressure shall be gradually raised at a rate of 0.1 N/mm2 per

minute.

If a drop in pressure occurs, the quantity of water added in order to reestablish the test pressure

should be carefully measured. This should not exceed 0.1 liter/ mm of pipe diameter per km of

pipeline per day for each 30 m head of pressure applied.

Failure to pass the test

All pipes or joints which are proved to be in any way defective shall be replaced or remade and

re-tested as often as may be necessary until a satisfactory test shall have been obtained. Any

work which fails or is proved by test to the unsatisfactory in any way shall be redone by

Contractor. No payments shall be made against replacement or remade and retested pipeline.

All pressure testing at site should be carried out hydrostatically. The pipes shall be accepted to

have passed the pressure test satisfactorily, if the quantity of water required to restore the test

pressure does not exceed the amount ‘Q’, calculated by the above formula.


If it is required to test a section of a pipe line with a free end, it is necessary to provide

temporary support against the considerable end thrust developed by the application of the test

pressure. The end support can be provided by inserting a wooden beam or similar strong

material in a short trench excavated at right angle to the main trench and inserting suitable

packing between the support and pipe end.

The pipeline stretch will pass the test if the water added during the test period is not exceeding

the admissible limits. No section of the pipe work shall be accepted b y the Engineer until all

requirements of the test have been obtained.

On completion of a satisfactory test any temporary anchor blocks shall be broken out and stop

ends recover. Backfilling of the pipeline shall be completed.

On completion of a satisfactory test any temporary anchor blocks shall be broken out and stop

ends removed. Backfilling of the pipeline trench shall be completed.

10.2 FAILURE TO PASS THE TEST

All pipes or joints which are proved to be in any way defective shall be replaced or remade and re-

tested as often as may be necessary until a satisfactory test shall have been obtained. Any work

which fails or is proved by test to be unsatisfactory in any way shall be redone by the Contractor.

TECHNICAL SPECIFICATION OF UPVC Pipes

Scope

The section of the tender document specifies the required properties of the

pipes made of un plasticized polyvinyl chloride (UPVC) with socket(s) suitable for

electrometric sealing ring type joints for conveyance of drinking water under

pressure. The pipes are intended to be used for water mains with ambient

atmospheric temperature reaching upto 50o C and soil surface temperature rising

to more than 65o C. The stipulations given in this document for UPVC pipe when

are not covered by any other

Material

The material from which the pipes are made shall consist substantially of un

plasticized polyvinyl chloride confirmed to ISI to which may be added actives

that are absolutely needed to facilitate the manufacture of the polymer and the

production of sound, durable pipes of good surfaced, finish, mechanical strength

and capacity. The total quantity of additives like plasticizers, stabilizers, lubricants

and filter shall not exceed more than 6.0 to 8.0 %. The density of UPVC pipe shall

be 1.39 to 1.44 g/cm3. The addition of the manufacturer’s own rework material

comply to clause 4.2 of IS 4985 PVC Resin of suspension grade K- 66 1 shall be

used for extrusion of UPVC pipe.

Classification

The pressure rating of pipes shall be of class – 3 in accordance with IS:4985

with a maximum continuous working pressure at 27o C of 6 and 10 kg/ cm3

respectively. This working pressure shall be downgraded for ambient underground

soil temperature of 45o C as per the Fig-1 given in IS: 4985 for design purposes.


Dimensions of the pipes and the sockets

The dimensions of pipes shall comply to the clauses given in IS: 4985. The

tolerance of outside diameter and wall thickness of pipes shall be as per Table-1

given in IS: 4985

The minimum depth of engagement ( U ) of single sockets with electrometric

seating ring type joint shall be in accordance with ISO: 2045 – 1988 ( E ).

The pipes shall be supplied in straight lengths of 6 m with tolerance of + 20

mm and –0 mm. The effective length of socket pipe shall be considered as shown in

Figure – 2 of IS: 4985.

Appearance and colour

The internal and external surface of pipes and fittings shall be smooth, clean

and free from grooving, cavities and other surface defects. The material shall not

contain visible impurities.

The end of the pipes shall be cut clearly and squire to the axis of the pipes.

The spigot end of the pipes shall be chamfered in accordance with Table 2.12.2 and

Drawing No. MS/TD/001.

The color of the pipes shall be dark grey.

Mechanical properties

Hydrostatic strength of the pipes

The pipes are subjected to internal hydrostatic pressure in according with IS:

12235- 1986 ( Part-8 ) shall not burst during the prescribed test duration. The

temperature duration of test and induced internal stress shall conform to the

parameters given below:

S.No Test Tempera

ture (oC)

Min.

duration

Induced stress

(Mpa)

Requiremen

t

1 Type test 60 1000 10 No Failure

2 Acceptance test 27 1 36 No Failure

Supply of pipes, marking

The pipes shall be supplied with one end plain with chamfer and other end

socket suitable for electrometric seating ring type joints in accordance with IS:

4985 and in accordance with IS: 4985 and in accordance with this requirement

Each piece shall be supplied along with a rubber pipe suitable for socket in

electrometric sealing ring type joints.


Each pipe shall be clearly marked in color at intervals of not more than 3 m

as indicated below:-

• Manufacturer’s name or trade mark

• Outside diameter in mm

• Class of pipe and pressure rating

• Month and year of manufacturing

• Length of pipe

• Marking of insert depth in spigot

• PHED – MB

• ISI marking To distinguish class – 3 and class-4 pipes more easily, sockets of all class – 3 and

class-4 pipes shall be marked with 5 cm wide band by green and yellow colure

respectively.

Tests and conformity criteria.

Testing of raw material

The following in house tests shall be carried out on the raw material

• Grade ( K – values )

• Particle size distribution

• Bulk density of resin

• Bulk density of compound

Quality control , tests and lot size

All u PVC pipes of the same size and class manufactured on a particular

machine shall be considered as a lot for quality control inspection. Hower, the

maximum size of a lot shall not be more than 1000 Pipes

The sampling procedure and scale of sampling for visual inspection and

dimensional requirements shall be as per Table-5 given in Appendix – A of IS: 4985.

The sample pipes from a lot shall be inspected for workmanship to ensure

that pipes is homogeneous through out, free from voids, cracks, inclusions and

other defects and uniform in color.

The pipes shall be inspected for surface finish. Quality socket dimensions

and length to ensure that pipes are free from sratch, bubbles. Over shape and are

of correct dimensions and length. The jointing surface of pies and spigot and

internal bell of the socket shall also be inspected to ensure that they are free from

any kind of damage and imperfections.

The measurement of the outside diameter and well thickness of the pipes

shall be done in accordance with Part – 1 and part – 2 of IS: 12235


Acceptance test

The pipes having satisfied for quality control requirements shall be selected

for acceptance.

The following acceptance tests shall be conducted in accordance with IS: 4985 and

IS 12235.

• Revision test.

• Stress relief test.

• Impact strength.

• Internal hydrostatic pressure test.

• Opacity

Type test

The following pipe test shall be conducted in accordance with IS: 4985 and IS:

12235.

• Influence on water quality ( Effect on water )

• Long tgerm hydrostatic pressure test ( 1000 Hours )

• VCM test.

Specifications for Providing, Laying, jointing, testing and sectional testing of pipelines

1. GENERAL

The contractor will inspect the route along which the pipeline is proposed to be

laid. The pipe alignment is duly marked on the field by demarcation pillars.

However efforts shall be made by the contractor to make minor deviations from the

marked alignment so as to keep the pipe alignment as straight as possible and to

avoid damage of public and private properties along the alignment. The alignment

of pipe line and location of specials & chambers may be changed at site in co-

ordination and with prior approval of the Engineer In Charge. The final alignment

on which the pipeline shall be laid shall be marked in field and got approved from

the Engineer in Charge or his representative.

Wherever there is need for deviation, it should be done with the use of necessary

specials or by deflection in pipe joints (limited to 75% of permissible deflection as

per relevant standards). The alignment as proposed should be marked on ground

with a line of white chalk and got approved from Engineer In-Charge. The position

of fittings, valves, shall be as per directions of engineer-in-charge.

2. Standards

Except otherwise specified in this technical specification, the Indian Standards and

Codes of Practice in their latest version, National Building code, PWD specification


of the state of Rajasthan and Manual of water supply of GOI shall be adhered to for

the supply, handling, laying, installation, and site testing of all material and works.

The laying of pipeline shall be done in confirmations to the following standards:

IS 6530-1972 for uPVC pipe lines.

3 .Tools and equipment

The contractor has to provide required tools and equipment required for the timely,

efficient and professional implementation of the work as specified in the time

schedule given in the special conditions of the contract. On demand he shall

provide to the Engineer in Charge a detailed list of tools and equipment available.

If in the opinion of the Engineer in Charge the progress or the quality of the work

cannot be guaranteed by the available quantity and type of tools and equipment the

contractor has to provide additional ones to the satisfaction of the Engineer in

Charge.

The Contractor will always have a surveyor and leveling instrument on site.

3.0 4. Earth Work

The Contractor shall furnish all tools, plant, instruments, qualified supervisory

personnel, labour, materials, any temporary works, consumables, any and

everything necessary, whether or not such items are specifically stated herein for

completion of the work in accordance with the Departments Requirements.

The excavation shall be carried out to correct lines and levels. This shall also

include, where required, proper shoring to maintain excavations and also the

furnishing, erecting and maintaining of substantial barricades around excavated

areas and warning lamps at night.

Excavated material shall be dumped in regular heaps, bunds, riprap with regular

slopes within the lead specified and leveling the same so as to provide natural

drainage. Rock/soil excavated shall be stacked properly as approved by the

Engineer in Charge. As a rule, all softer material shall be laid along the center of

heaps, the harder and more weather resisting materials forming the casing on the

sides and the top. Rock shall be stacked separately.

Topsoil shall be stock piled separately for later re-use.

5. Clearing

The area to be excavated/filled shall be cleared of fences, trees, plants, logs,

stumps, bush, vegetation, rubbish, slush, etc. and other objectionable matter. If

any roots or stumps of trees are encountered during excavation, they shall also be

removed. The material so removed shall be disposed off as approved by the

Engineer in Charge. Where earth fill is intended, the area shall be stripped of all


loose/ soft patches, top soil containing objectionable matter/ materials before fill

commences.

6. Laying and jointing of pipes

The laying of uPVC pipes shall be as per the provisions of IS 6350, however the

specific references given herein shall prevail on the provisions of the standards.

Pipes should be lowered into the trench with tackle suitable for the weight of pipes.

For smaller sizes, up to 200 mm nominal bore, the pipe may be lowered by the use

of ropes but for heavier pipes suitable mechanical equipment have to be used.

All construction debris should be cleared from the inside of the pipe either before or

just after a joint is made. This is done by passing a pull-through in the pipe, or by

hand, depending on the size of the pipe. All persons should vacate any section of

trench into which the pipe is being lowered.

On gradients of 1:15 or steeper, precautions should be taken to ensure that the

spigot of the pipe being laid does not move into or out of the socket of the laid pipe

during the jointing operations. As soon as the joint assembly has been completed,

the pipe should be held firmly while the trench is back filled over the barrel of the

pipe. Suitable transverse anchors shall be provided in sloping reaches as defined

herein after.

The designed anchorage shall be provided to resist the thrusts developed by

internal pressure at bends, tees, etc.

Where a pipeline crosses a watercourse, the design and method of construction

should take into account the characteristics of the watercourse to ascertain the

nature of bed, scour levels, maximum velocities, high flood levels, seasonal

variation, etc. which affect the design and laying of pipeline. The pipe shall be laid

accordingly with adequate protection. The pipes in such cases shall be laid below

ground with anchor blocks of suitable size and design.

The assembly of the pipes shall be made as recommended by the pipe

manufacturer and using the suitable tools.

The socket and spigot ends/other ends of the pipes shall be brushed and cleaned.

The chamfered surface and the end of the spigot end has to be coated with a

suitable lubricant recommended by the manufacturer of the pipes. Oil, petroleum

bound oils, grease or other material which may damage the rubber gasket shall not

be used as lubricant. The rubber gasket shall be inserted into the cleaned groove of

the socket. It has to be checked for correct positioning. For uPVC pipes procedure

as mentioned in IS 6530 is to be followed. Generally uPVC coupling is used for

joining uPVC pipes. In some cases, CID joints may also be used.

The two pipes shall be aligned properly in the pipe trench and the spigot end shall

be pushed axially into the socket either manually or with a suitable tool specially

designed for the assembly of pipes and as recommended by the manufacturer. The


spigot has to be inserted up to the insertion mark on the pipe spigot. After

insertion, the correct position of the socket has to be tested with a feeler blade.

7. Testing of the pipelines

After laying and jointing, the pipeline shall be tested by the contractor and all

pipes or joints which are proved to be in any way defective shall be replaced or

remade and re-tested as often as may be necessary until a satisfactory test shall

have been obtained. Any work which fails or is proved by test to be unsatisfactory

in any way shall be redone by the Contractor.

For Pipe line and other materials at site in tenders of works

Sn Item Payment of quoted cost

1 90% after receipt of material in good its laying jointing/ erection Installation at site and sectional testing of pipeline (Including all the tests required in the manufacture premises acceptance of the inspection & testing reports submission of other papers warranties required as per the conditions of contract for the material supplied

90%

2 10% after successful commissioning of work final site clearance and complete trial run.

10%

Signature of Contractor

Executive Engineer PHED District (R) Dn.II

Bikaner

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