SECTION 02610

PIPE AND PIPE FITTINGS

PART 1 – GENERAL

DELETE REFERENCE TO SECTION 01012 WHERE NOT APPLICABLE.

1.1 DESCRIPTION OF WORK

A. This specification section applies to underground utilities piping required for site
development work. For pipe work inside the buildings and process piping work,
refer to specifications in Division 15.

B. Related Work:

1. Section 01086: Color Codes and Color Standards

2. Section 02200: Earthwork
3. Section 02617: Steel Pipe
4. Section 02615: Ductile Cast Iron Pipe (DCI)
5. Section 02622: Plastic Pipe (uPVC)
6. Section 02623: Glass Fiber Reinforced Plastic Pipe (GRP)
(For Service other than Seawater System)
7. Section 09875: Corrosion Resistant Coatings

1.2 QUALITY ASSURANCE

A. Reference Standards: The latest editions of the following standards shall apply:

1. American Standards:

a. American Society for Testing and Materials (ASTM):

ASTM A 449 Quenched and tempered steel bolts and studs,

Spec. for

b. American National Standards Institute (ANSI):

RCMYAS Guide Spec. 02610-1 Contract No.

Rev. J, 11 Feb’ 06
 ANSI A 21.51 Polythene and ductile cast-iron piping for water
and other liquids

ANSI B 18.2.1 Square and hex bolts and screws including hex
head cap screws and lag screws

ANSI B 18.2.2. Square and hex nuts

ANSI B 31.3, Petroleum refinery piping

ANSI B 16.3 Malleable-iron threaded fittings

c. American Water Works Association (AWWA):

AWWA C 110, Gray-iron and ductile-iron fittings, 3 in. through

48 in., for water and other liquids

d. American Petroleum Institute (API):

API 5 L, Specification for line pipe.

2. International Standards:

a. International Organization for Standardization (ISO):

ISO 1461, Metallic coatings - Hot dip galvanized coatings

on fabricated ferrous products - requirements.

ISO 2507, Unplasticized polyvinylcholoride (uPVC) pipes -

Determination of Vicat softening temperature.

ISO 2531, Ductile iron pipes, fittings and accessories for

pressure pipe- lines.

ISO 3458, Assembled joints between fittings and

polyethylene (PE) pressure pipes - Test of
leakproofness under internal pressure.

ISO 3459, Polyethylene (PE) pressure pipes - Joints

assembled with mechanical fittings - Internal
under-pressure test method and requirements.

ISO 3501, Assembled joints between fittings and

polyethylene (PE) pressure pipes - Test of
resistance to pull out.

RCMYAS Guide Spec. 02610-2 Contract No.

Rev. J, 11 Feb’ 06
 ISO 3503, Assembled joints between fittings and
polyethylene (PE) pressure pipes - Test of
leakproofness under internal pressure when
subjected to bending.

ISO/DIS 4422, Unplasticized polyvinylchloride (uPVC) pipes

and fittings for water supply - Specification.

3. German Standards:

a. Deutsches Institute fur Normung e.V. (DIN):

DIN 2632, Welding neck flanges; nominal pressure 10

4. British Standards:

a. British Standards Institution (BS):

BS 1400, Copper alloy ingots and copper alloy castings

BS 2494, Materials for elastomeric joint rings for

pipework and pipelines.

B. Source Quality Control: The following tests shall be performed:

1. All steel fittings shall be tested in accordance with API Spec. 5 L, but at a
minimum hydrostatic test pressure of 1.5 MPa.

2. All cast iron fittings shall be tested in accordance with AWWA C110, but at
a minimum hydrostatic test pressure of 1.5 MPa.

3. All ductile iron fittings shall be tested in accordance with AWWA C110, but
at a minimum hydrostatic test pressure of 1.5 MPa in accordance with
additional test, Section 10-12 in this standard or in accordance with ISO
2531 but with the same minimum hydrostatic test pressure.

4. UPVC fittings shall be tested in accordance with ISO/DIS 4422. In

addition, the following tests shall be carried out:

a. Determination of resistance to internal hydrostatic pressure in

accordance with ISO/DIS 4422, Clause 6.2, Quality Test (1,000
hour test). The tests shall be performed at nominal pressure.

RCMYAS Guide Spec. 02610-3 Contract No.

Rev. J, 11 Feb’ 06
 b. Determination of resistance to external blows on five samples from
the batch. The test shall be carried out in accordance with ISO/DIS
4422, Clause 6.1.2.1.

c. Determination of the Vicat softening point in accordance with ISO

2507.

d. If the total number of uPVC fittings exceeds 3000, one set of

additional tests shall be carried out for every batch of 3000.

5. Assembled Joints for HDPE Pipe:

a. Metallic or plastic connections are to be tested in accordance with

ISO 3458, ISO 3459, ISO 3501 and ISO 3503 except that the
prescribed tests of the above named standards shall be carried out
at temperature of both plus 20 and 40°C.

b. Injection molded plastic connections of uPVC shall be tested in

accordance with ISO/DIS 4422. For every batch of connections
delivered, the same tests shall be carried out as required for uPVC
fittings.

1.3 SHOP DRAWINGS

A. Shop drawings showing all fittings, valves etc. and assembly thereof, shall be
prepared for all underground installations. A bill of materials shall be included
that will show all valves and fittings in underground chambers, with assigned
identifying mark numbers and the material that these are made from.

B. Requests for approval of material for valves and fittings shall be accompanied by
catalog cuts, copies of approved shop drawings and the intended location/system
where the fittings will be installed.

PART 2 – PRODUCTS

2.1 GENERAL

A. All goods and products covered by these specifications shall be procured, when
available, from an in-kingdom manufacturer. Procurement of all goods and
products manufactured out-of-Kingdom must be approved by the Royal
Commission.

B. For color code requirements for utility piping systems, see Section 01086, Color
Codes and Color Standards.

RCMYAS Guide Spec. 02610-4 Contract No.

Rev. J, 11 Feb’ 06
2.2 MATERIALS

A. Steel Fittings:

1. Welding Fittings: Steel fittings shall comply with API Spec. 5 L for
seamless or welded pipe. For the design and calculation of the minimum
wall thickness of the fittings, the internal working pressure, external earth
load, traffic load, etc., shall be specified. The wall thickness shall under
no circumstances be less than:

External diameter (mm) Wall thickness (mm)

323.9 5.6
404.6 6.3
508.0 6.3
812.8 9.5
1061.0 10.0
1219.0 10.0

Bends shall be smooth with the radius of at least 1.5 times the nominal
diameter. Tees shall either be of the extruded welding type or of the
direct welded branch type. Reducers shall be made with a length
L = 3 (OD-Od), where L is the construction length, OD the outer diameter
of the large end and Od the Outer diameter of the small end.

2. Threaded Fittings: Threaded fittings shall comply with ANSI B16.3 and be
hot dip galvanized in accordance with the relevant standards. The
minimum thickness of the zinc layer shall be 120 micrometers.

B. Cast Iron Fittings: Cast iron fittings shall comply with AWWA C110.

C. Ductile Cast Iron Fittings: Ductile cast iron fittings shall comply with AWWA
C110 or ISO 2531. Fittings complying with ISO 2531 shall be of at least class K
= 14 for tees and K = 12 for other fittings.

D. uPVC Fittings: All uPVC fittings and joining material shall comply with ISO/DIS
4422. However, the Vicat softening point and K-value shall not be less than plus
76 and 61 degrees C respectively. uPVC pressure fittings shall comply with
Class 1.6 MPa (16 kg/cm2) of the metric series. Non-pressure uPVC fittings shall
comply with 0.6 MPa (6 kg/cm2) of the metric series. For pipe sizes 63 mm
nominal diameter and below, use solvent welded fittings. For sizes larger than
63 mm nominal diameter, use socket fittings with flexible rubber ring joints. All
threaded fittings shall be connected to the pipes by use of threaded coupling
adaptors or by installation of Schedule 80 uPVC nipples, Type 1, Grade 1, ASTM
D1784, D1785 and D2464.

RCMYAS Guide Spec. 02610-5 Contract No.

Rev. J, 11 Feb’ 06
2.3 FABRICATION AND MANUFACTURE

A. General: External and internal surfaces of all fittings of steel, ductile iron, and
cast iron shall be coated in accordance with Section 09875.

B. Pipe and Pipe Fittings: Pipe shall be as long as practicable with regard to
reducing the number of joints, but not longer (excluding the socket, if any) than
6.0 m for uPVC, DCI and CIP. Steel pipe shall have an average length of about
10 m. If the manufacturer of GRP pipe normally produces pipe longer than 6.0
m, this length may be accepted on special request.

C. All metallic surfaces in contact with or exposed to soil including valves, couplings,
adaptors and pipes, shall be wrapped with adhesive waterproofing tape or
polythene encasement as approved by Royal Commission. Before taping,
irregular contours shall be filled in with filler mastic.

D. Bolts and Nuts:

1. Bolts, nuts, and washers for flange connections shall be of hot dip
galvanized steel with at least 120 micrometers of zinc in accordance with
ISO 1461. Bolts and screws shall comply with ANSI B 18.2.1, specification
ASTM A 449.

2. Nuts shall comply with ANSI B 18.2.2.

3. Bolts, nuts, and washers which will be exposed to the soil or which are
below water table shall be made of stainless steel, grade 316L.

4. The length of thread protruding from the tightened nut in bolt couplings
shall be equivalent to at least once and at most twice the bolt diameter.

5. Flange connections with bolts and nuts exposed to the soil shall be
wrapped with adhesive coal tar water proofing tape.

E. Rubber Joint Rings: Rubber joint rings shall be free from any substances which
could affect the water and shall in all respects be resistant to water having the
characteristic properties given in Section 02713. Attention is again drawn to the
extreme conditions in the country such as the high air temperature. Rubber joint
ring to be used for potable water system shall be ethylene propylene rubber
(EPDM). Nitrile Rubber (NBR) shall be used for sewer system rubber joint rings.

F. Bends, Elbows, Reducers and Tees:

1. All bends, reducers, and tees for uPVC pipes size 63 mm nominal
diameter and below shall be solvent weld type. Sizes larger than 63 mm
diameter shall be flexible rubber ring joint type.
RCMYAS Guide Spec. 02610-6 Contract No.
Rev. J, 11 Feb’ 06
 2. All bends, reducers, and tees for FRP pipes shall be FRP, plain ended
type, compatible with Amiantit double bell Reka couplings.

3. Bends, reducers and tees to be installed inside valve chambers shall be

made of carbon steel, ductile iron, cast iron, bondstrand or FRP.

4. New branch tee material for connection to existing asbestos cement pipe,
shall be FRP suitable for ACP Class 24.

G. Couplings:

1. General: Couplings shall permit the connection of two pieces of pipe

without displacing the pipe longitudinally. The couplings will be used for
fitting closing lengths on pipelines, for withdrawing a pipe for cleaning or
inspection or for repair purposes and shall thus not be supplied with any
center register. Metallic coupling may be used upon prior approval from
Royal Commission and shall be coated in accordance with Section 09875.
In addition, the external surfaces shall be wrapped with adhesive
waterproofing tape or polythene encasement as directed by Royal
Commission.

2. uPVC Couplings: Couplings for uPVC pipe of 280 mm diameter or less

shall be class 5 with rubber gaskets for water distribution systems and
force mains; and shall be class 3 for sanitary and other gravity systems.

3. GRP Couplings: Couplings for glass fiber reinforced plastic pipe shall be
made of GRP, double bell Reka type coupling.

4. Repair Couplings: Repair couplings shall be used for repairing uPVC or

GRP pipe and shall be manufactured in accordance with AWWA C110 or
ISO 2531. The coupling shall be made of uPVC or GRP.

5. Stepped Couplings: Stepped couplings shall be used for connection of

dissimilar pipe diameter and be made of carbon steel, ductile iron or cast
iron. All metal surfaces shall be coated in accordance with Section 09875.
In addition, all external surfaces shall be wrapped with adhesive
waterproofing tape or polyethylene encasement as directed by Royal
Commission.

6. Dismantling/Detachable Joint: Detachable or dismantling joint shall be

installed and used for pipework inside Air Release/Vacuum, Isolation and
Washout valves in chamber, water metering chamber and lift station
valve/diversion chamber.

RCMYAS Guide Spec. 02610-7 Contract No.

Rev. J, 11 Feb’ 06
H. Adaptors:

1. Double Socket Adaptors - uPVC/GRP/Steel /DCI: Double socket adaptors

suitable for use between spigot ends of uPVC, glass-fiber reinforced
plastic, carbon steel or ductile iron pipe shall be made of steel, ductile iron,
GRP or cast iron.

2. Double Spigot Adaptors Suitable for use:

a. uPVC/GRP, uPVC/DCI or GRP/Steel: Double spigot adaptors

suitable for use between socket ends of glass fiber reinforced
plastic or ductile iron pipe, and sockets formed for connection with
uPVC, shall be made of steel, ductile iron, GRP or cast iron and
shall have corrosion resistant coating.

3. Socket/Spigot Adaptors - DCI/uPVC: Socket/spigot adaptors suitable for

use between spigot ends of ductile iron pipe and socket ends of uPVC
pipe shall be made of steel, ductile iron, GRP or cast iron.

4. Flanged Adaptors: Flanged adaptors used for jointing steel/uPVC,

uPVC/uPVC, Steel/Steel or DCI/DCI shall be made of steel, ductile iron,
cast iron or GRP. All metal surfaces shall be protected with corrosion
resistant coating per Section 09875.

I. Fittings in Meter/Valve Chambers:

1. All pipe spools in chambers shall be made of GRP, or stainless steel, as

approved by the Royal Commission.

2. Dismantling/detachable joint(s) shall be installed in valve chamber to

facilitate ease of maintenance of pipe spools, valve and fittings.

3. The required minimum clearance between wall/slab and flanged

spool/coupling as well as valve shall be 500 mm. A minimum clearance of
150 mm shall be maintained from top of any fitting or valve to the
underside of the top slab.

4. All metal surfaces shall be protected with corrosion resistant coating, refer
to Section 09875.

J. Flanged Couplings:

1. The couplings shall be in accordance with the drawings with regard to

location, type and dimension.

RCMYAS Guide Spec. 02610-8 Contract No.

Rev. J, 11 Feb’ 06
 2. The couplings shall be made of steel or GRP. Bolts and nuts shall be as
specified.

3. Flanges:

a. Cast iron or ductile iron flanges shall comply with ISO/R 13 or with
ISO 2531 class PN 16 respectively.

b. The flanges for steel pipework shall be welding neck type

complying with DIN 2632. The corrosion protection applied on the
internal surfaces of pipe and fittings shall also be applied on the
flange face. The finish of the coating on the sealing surface must
meet the gasket sealing requirements.

K. Blind Flanges: When pipelines are to be closed, blank flanges made of steel,
stainless steel, ductile iron, cast iron, uPVC or GRP shall be used.

L. All metallic surfaces in valve and other chambers, as well as those in contact with
soil, shall be coated with corrosion resistant epoxy paint in accordance with
Section 09875. In addition, all metallic surfaces in contact with soil shall be
wrapped with adhesive waterproofing tape or polythene encasement as directed
by Royal Commission. Before taping, irregular contours shall be filled in with
filler mastic.

M. Two (2) repair and two (2) universal couplings and one (1) meter spool piece for
flexibility shall be installed outside the new meter and valve chambers on each
side.

PART 3 – EXECUTION

3.1 PREPARATION

A. See Section 02200 and specific usage section.

B. Pipe Laying:

1. Regardless of which pipe material is used, the manufacturer's installation

instructions shall be followed.

2. The Contractor shall ensure that all pipelines are placed within the
assigned area in the actual cross-section. Before any pipe or fitting is
lowered into the trench, it shall be carefully checked to ensure that it is not
cracked or damaged in any way. Depending on the Royal Commission's
decision, damaged pipe shall either be cut, so that flawless pipe is

RCMYAS Guide Spec. 02610-9 Contract No.

Rev. J, 11 Feb’ 06
 obtained with least possible waste and so that the protective covering and
lining, if any, is not damaged, or the whole pipe shall be rejected. The
outer coating, if any, is to be inspected and any defects made good. All
foreign matter such as soil, rags, etc., is to be removed from the interior of
the pipe.

3. All lumps, blisters and excess coating shall be removed from the ends of
all pipes and fittings and the joints shall be brushed and wiped clean and
free from oil and grease before the pipe is laid.

4. When placing pipe in the trench, fabric slings shall be used at the
balancing points. The pipe shall not be dragged along the bottom of the
trench, nor humped, and it shall be supported by the sling while being
fitted to the adjacent pipe. Should there be a coating on the underside of
the pipe, it shall be inspected while the pipe is suspended from the sling
and any damage to the coating shall be repaired before the pipe is
lowered into the trench. No metal tools or heavy objects should be
permitted to come into unnecessary contact with the pipe or fittings. All
damage to the protective coating from any cause shall be repaired.

5. The pipe shall be laid at the level and gradient stipulated, on a prepared
bed 150 mm deep with special hollows made for the joints. The pipe shall
be aligned carefully in both the horizontal and vertical planes and at no
point be laid more than 10 mm from the theoretical straight line; for plastic
pipe 20 mm. Supports must not be placed under the pipe.

6. Every precaution shall be taken to prevent foreign matter from entering the
pipe or fittings. During laying operations, no debris, tools, cloth or other
materials are to be allowed to enter the pipe. After placing a length of pipe
with socket/spigot joints in the trench with the socket end upstreams, the
spigot end shall be centered in the socket (or similar) and the pipe forced
home and brought to correct line and grade. The angle between any
piping or fittings shall not exceed the manufacturer's recommendations.
The pipe and fitting shall be secured in place with approved backfill
material tamped under it except at the joints.

7. At times when pipe laying is not in progress, the open ends of the pipe
shall be sealed by watertight plugs supplied by the Contractor.

8. All pipelines shall be inspected and approved by the Royal Commission

before they are back filled.

C. Field Coating:

1. Repair of Factory Coating: After joining, damage to the coating on pipe,

fittings, valves, etc., shall be carefully repaired with approved coating to

RCMYAS Guide Spec. 02610-10 Contract No.

Rev. J, 11 Feb’ 06
 original standard. Before field coating, the surfaces shall be dry and free
from grease, oil and other foreign matter. A reasonable quantity of coating
material for repair work shall be included.

2. Flange Protection: Corrosion protection tape shall be wound round any

flange joints after which a polythene encasement shall be applied in
accordance with ANSI A 21.51. Before taping, irregular contours shall be
filled-in with filler mastic. All material used for flange protection shall be
delivered to and applied by the Contractor.

D. Flanges: Flange connections shall be located in valve chambers or elsewhere

above ground. Flange connections buried in the ground are not allowed except
on fire hydrants’ underground pipe connections as shown on RC standard
drawing No. RC-C-3.

E. Bolts, Nuts, and Washers:

1. See Clause 2.3 in this Section.

2. Washers shall be placed under both nuts and bolt heads.

F. Rubber Ring Joints: Where rubber ring joints are to be used, the instructions
issued by the manufacturer of the rings shall be followed carefully. When joining
pipe, a mark shall be made to check the position of the end of the pipe unless it
has a marking ring. In view of the flexibility of the joint, a gap shall be left
between the ends of the pipe in accordance with the manufacturer's
recommendations. For asbestos cement pipe, this gap shall be at least 15 mm in
order to compensate for the expansion due to water absorption. When the
connection is complete, the ends of the pipe are to be checked by means of the
mark. When pipe is laid at curves, the pipe may not be bent sideways until the
connection has been made. Bolts shall be tightened up gradually so that the
coupling is drawn together uniformly.

3.2 FIELD QUALITY CONTROL

A. Hydrostatic Test:

1. After completing the installation of a pipeline or section, hydrostatic tests

of the line shall be made as soon as possible. The initial hydrostatic test
shall be made with partial backfilling keeping all joints exposed. For 300
mm diameter pipe and larger, the length of the piping being tested shall
not be more than 3 km.

2. The tests on lines for potable and fire water shall be carried out using
potable water.

RCMYAS Guide Spec. 02610-11 Contract No.

Rev. J, 11 Feb’ 06
 3. Parallel lines with common thrust blocks are to be tested one at a time.

4. Before the first hydrostatic test is carried out, permanent and temporary
supports shall be installed. Thrust blocks and valve chambers shall be
cast not less than 7 days before the test is carried out and backfill shall be
placed around all thrust blocks and valve chambers.

5. The tested sections shall be provided with stop ends; the use of valves to
close off the tested section will not be permitted. Simple stop ends are to
consist of flanged socket or spigots with blank flanges containing the
necessary openings for accommodating in-coming water and outgoing air.

6. The stop end may also include an opening through which the test water
may be pumped from the line should it prove necessary. Thrust blocks
shall be provided to hold the stop ends in place against the test pressure.
These may take the form of concrete abutments on either side of the
trench with steel joists spanning between them. The stop end is to be
braced against the thrust block by screw jacks and wedges.

7. The trench shall be backfilled with sand to 300 mm above the pipe and
compacted in accordance with Section 02200 – “Earthwork.”

8. The line shall be filled at low point and care shall be taken to remove all
the air. To prevent possible water hammer, the velocity of the water in the
pipe shall not exceed 0.05 m/sec. For proper filling of the pipe with water,
allow the water to reach the same temperature as the pipe and for
removal of all air.

9. The initial hydrotest pressure shall be 70% of the required test for a period
of at least 24 hours, after which the trench shall be carefully inspected for
evidence of leakage.

10. The test pressure shall be applied by means of a motorized or a hand

pump connected to the pipe in a manner approved by Royal Commission.
The pressure meter shall have an accuracy of + 10 kPa (0.1 kp/cm2)
within the range of pressures in question.

11. The pumps and all necessary apparatus for the test shall be furnished by
the Contractor. The pipe in the partially backfilled trenches shall be
carefully examined during the test. All joints showing leaks shall be
rejointed until tight or the pipe material replaced. Any cracked or defective
pipes, fittings or valves discovered as a result of this pressure test shall be
removed and replaced by the Contractor with sound material after which
the test shall be repeated.

RCMYAS Guide Spec. 02610-12 Contract No.

Rev. J, 11 Feb’ 06
 12. If the pressure should fall by more than 20%, water shall be pumped into
the pipe until the test pressure is reached.

13. When the pressure required is reached and applied for 24 hours, the
allowable 5% pressure drop shall be calculated. Upon approval from
Royal Commission, the leakage calculation in liter per kilometer per 24-
hours can be performed in lieu of pressure drop method.

14. When leakage method is directed by Royal Commission, no section of the

pipe will be accepted until the leakage calculation in liters per km (pro-
rated for lesser distance) per 24 hours at the test pressure is less than:

Liters per km
Per 24-hours Ø Pipe (mm)

20 100 (110 mm Ø UPVC)

40 150 (160 mm Ø UPVC)
60 200 (225 mm Ø UPVC)
100 300
140 400
180 500
220 600
290 800
380 1,000

15. The Contractor shall, as soon as possible after the approved initial
hydrostatic test, start and complete backfilling the entire trench up to
ground level or subgrade of pavement in accordance with Section 02200 –
“Earthwork”.

16. The final hydrostatic test shall be performed when the backfilling has been
completed up to ground level or subgrade of pavement and compacted in
accordance with Section 02200. Final hydrotest shall not be performed
unless all interior test end points have been connected.

17. Interior test end points or joint adjoining two tested sections shall be tested
by closing adjacent isolation valve(s) in one test section and pressurizing
the other tested section.

18. Single joint between interior tested sections can be tested with the water
mains working pressure, provided it is approved by Royal Commission
Water & Sanitary Sewage Department.

19. The final hydrostatic test pressure for all distribution lines and force mains
shall be:

RCMYAS Guide Spec. 02610-13 Contract No.

Rev. J, 11 Feb’ 06
 Hydrotest Pressure
Maximum (1.03 MPa Minimum or
Operating 1.5 x Maximum Operating
System Pressure Pressure whichever is greater)

Potable Water 0.60 MPa 1.03 MPa

Irrigation Water 0.60 MPa 1.03 MPa
Process Water 0.70 MPa 1.05 MPa
Reclaimed Water 0.75 MPa 1.13 MPa
Force Mains - 1.30 MPa

3.3 WARNING TAPE

A. After initial hydrostatic test is accepted by Royal Commission, warning tape shall
be installed at 300 mm above the top of the pipe. The following, as applicable,
shall be printed on the tape in both Arabic and English, in durable black letters of
50 mm height.

"Caution - Potable (or Fire/Reclaimed/Irrigation/Process/ Sanitary

Sewer) waterline below."

+ + END OF SECTION 02610 + +

RCMYAS Guide Spec. 02610-14 Contract No.

Rev. J, 11 Feb’ 06