IRRIGATION SYSTEMS - TECHNICAL SPECIFICATIONS VOLUME III

20. HDPE PIPES (SECTION 02650)

20.1. Part 1 General

20.1.1 Scope
A. This Material Specification details the minimum requirements for the design,
manufacture, testing, inspection and supply of High Density Polyethylene (HDPE
or High Performance Polyethylene (HPPE pipe material and fittings used in
irrigation systems.

20.1.2 Related Documents

A. The following sections of the specification shall be read in conjunction with
this section.

Section 01300 Submittals

Section 01400 Quality Control
Section 01600 Material and equipment
Section 02222 Excavation
Section 02223 Backfilling
Section 02225 Trenching
Section 15121 Pipe Expansion Compensation
Section 15245 Vibration Isolation
Section 15140 Pipe Supports

20.1.3 Applicable Standards and Codes

A. The following codes and standards, to the extent specified herein, form a part of
this specification. The latest edition of these codes and standards shall govern
the work.

ISO 4427 Polyethylene (PE pipes for water supply specifications

ISO 161-1 Thermoplastic pipes for conveyance of fluids nominal
outside diameter and nominal pressure- part 1: Metric series
ISO 1167-1to4 Thermoplastic pipes, fittings and assemblies for the
conveyance of fluids
ISO 3126 Plastic pipes Measurement of dimensions
ISO 4065 Thermoplastic pipes Universal wall thickness table
ISO 6964 Polyolefin pipes and fittings Determination of carbon black
content by calcination and pyrolysis Test method and basic
specification.
ISO 9080 Thermoplastic pipes for the transport of fluids Method of
extrapolation of hydrostatic stress rupture data to determine
the long-term hydrostatic strength of thermoplastic pipe
materials.

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ISO 11922-1 Thermoplastic pipes for the conveyance of fluids Dimensions and
tolerances Part: 1: Metric series.
ISO 12162 Thermoplastic materials for pipes and fittings for pressure
applications Classification and designation overall service
(design coefficient.
ISO 13761 Plastic pipes and fittings pressure reduction factors for polyethylene
pipeline systems for use at temperatures above 200C.
ISO 7005 3 Metallic flanges Part 3, Copper alloy and composite flanges
BS EN 12201 Plastic piping systems for water supply - polyethylene
ISO 974 Determination of the brittleness temperature by impact
ISO 2505 Thermoplastics pipes - Longitudinal reversion
ISO 6259 Determination of tensile properties
ISO 1133 Determination of the melt mass-flow rate (MFR) and the melt
Volume - flow
ISO 877 Methods of exposure to direct weathering

20.1.4 Submittals

20.1.4.1 Products and Materials Approval.

A. In order to verify compliance with the specification the Contractor shall submit
information for all products and materials used in the Works to the Engineer for
approval sufficiently in advance of their use in accordance with the Contract
programme allowing for ordering and approval times. Reference shall also be
made to Section 01600 of the specification on products and materials approval.
Information to be submitted shall comprise but not necessarily be limited to:

i. The manufacturers design calculations, complete and detailed specification

and test results of the proposed HDPE pipes and fittings required for the
Works inc
the standard specification. Information on all items listed in Table 20.1-1
below shall be given for every diameter in each class of pipe.
ii. Should any details of the pipes and fittings be altered in any way during
manufacture from those proposed and approved by the Engineer, submit for
the Engineer's approval the revised details and test results.
iii. Submit to the Engineer the results of all quality control tests carried out on
the manufactured pipes and fittings as soon as practicable after testing as
and in any case not later than the time of delivery of the relevant pipes and
fittings to the site.

Table 20.1-1: Product Information for HDPE Pipe and Fittings

Product Information Units

Manufacturing Details
Name of manufacturer -
Manufacturing process for pipes -
Manufacturing process for bends and fittings -
Joint type -

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Details of all additives used in the manufacture -

Polymer classification and certificate of origin -
Summary of Design Criteria
Rated working pressure MPa
Design test pressure (165hrs or 100 hrs.) MPa
Internal vacuum pressure MPa
Minimum required strength (MRS) MPa
Pipe Details
Nominal external diameter mm
Wall thickness mm
Standard dimension ratio (SDR) -
Standard pipe length m

20.1.4.2 Method Statements

A. The Contractor shall submit method statements to the Engineer for approval 4
weeks in advance of commencing the site activity in accordance with Section
01300 of the specification. These shall comprise but not necessarily be limited to:

i. Procedures for handling, storage and installation of pipes.

ii. Procedures for building pipes into concrete structures.
iii. Hydrostatic testing procedures for HDPE pressure pipelines.

20.1.4.3 Drawings
A. The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance with Section 01300 of the
specification. These shall comprise but not necessarily be limited to:

B. Drawings of the pipes, fittings, joints, pipe specials and the assembly thereof.

C. Pipe laying diagram and schedule showing location, length, design designation
and designation by number of each pipe section and pipe special to be furnished
and installed.

D. All data on curve and bends for both horizontal and vertical alignment.

20.1.5 Quality Control

A. Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the
opportunity to inspect and test the product and/or material prior to delivery in
accordance with Section 01400 of the specification.

B. Products and materials shall be from a manufacturer/supplier who operates a

quality system which is registered to ISO 9000 series or approved equal.

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C. To allow the Engineer to inspect the Works the Contractor shall give the

site:
i. Installation of pipeline.

ii. Hydrostatic testing of pipeline.

20.1.6 Delivery, Storage, and Handling

A. Delivery, storage and handling of products and materials shall be in accordance

and the following provisions.

i. Delivery storage and handling shall at all times be performed in a manner to

recommendations.
ii. Pipes and fittings shall not come in contact with any sharp projections that
may cause damage to the pipes and fittings during transportation loading and
unloading. Ensure that pipes and fittings are well secured during transit and
adequately supported along their length. Do not allow pipe to overhang the
end of a vehicle during transportation.
iii. Ensure that pipes and fittings are lifted using nylon or large diameter rope
slings positioned at a quarter of the pipe length from each end. Do not allow
the use of wire rope chains or unpadded forks or clamps on forklifts to lift
pipes.
iv. Store pipes and fittings on a flat level area as recommended by the pipe
manufacturer. Ensure that pipes and fittings supplied either on pallets or
crated, remain on the pallets or in their crates until required.
v. Stack non-crated pipes to the approval of the Engineer.
Stack pipes of different sizes and thickness separately.
Do not allow stacked pipes to exceed 2m in height or as recommended by
the supplier whichever is the lesser.
vi. The Contractor shall visually inspect all products upon delivery to site and
report any damage to the Engineer.
Any products damaged during delivery, storage and handling shall be
marked by the Contractor and set aside.
Proposals for repair of any damaged products shall be submitted in
writing to the Engineer for approval.
Any damaged products deemed unsuitable for repair by the Engineer
shall be removed from site and replaced.
Scratching or scoring of pipe surface to a depth greater or equal to 10%
of wall thickness shall constitute an automatic rejection of that pipe
section.

20.2. Part 2 Products

20.2.1 Technical Requirements

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20.2.1.1. Material Requirements

A. The CONTRACTOR shall identify the manufacturer of the resin, the resin type
and classification. In addition, the CONTRACTOR shall provide evidence that the
resin proposed is suitable for use at the design temperature and under the
design pressures indicated.

B. Any change in the material, the material specification, or the manufacturer's

location shall be subject to prior approval of the Client/End users/ENGINEER.

C. Pipes and fittings shall be homogenous throughout and free from visible cracks,
holes, foreign inclusions, blisters, dents or other damaging defects.

D. Material shall be uniform in opacity, density, interior smoothness, and other

physical properties. It shall have adequate resistance to weathering and other
ageing from storage for a minimum of two years after manufacture.

E. For the manufacturing of pipes & fittings only new materials to be used (Rework
material is not acceptable.

F. Pipe manufacturer shall confirm that all fittings to be provided for the pipe
systems shall meet the same quality requirements as for the pipes to ensure the
same performance for design life cycle.

G. The pipes and fittings shall be manufactured from polyethylene containing only
those antioxidants, UV stabilizers and pigments necessary for the manufacturing
process to fulfill the requirements of the specification.

H. All pipes and fittings shall be suitable for butt fusion or electro fusion techniques.
Contractor shall provide PE manufacturers guideline for the applicability of the
material used. If required PE manufacturers shall provide assistance and
training.

20.2.1.2. Physical Properties

A. Pipes and fittings shall be made of high density polyethylene (HDPE) and shall
comply with the requirements of ISO 4427 PE 100. The material shall be
produced by a member of the PE 100 + Association.

B. The material used for the manufacturer of pipes and fittings shall be in
accordance with Table 1 and Table 2 of clause 4.4 of ISO 4427-1

C. The minimum required strength (MRS) of the material compound shall be 10

MPa at 200 C. The design stress shall be 8 MPa.

D. Lifecycle durability of 80 years is to be confirmed.

E. The design temperature shall be 36º C

F. For design calculation, pressure, reducing coefficients 4427-1, Annex A are

applicable. The thermal stability of polyethylene material shall meet the
requirements of ISO 4427.

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20.2.1.3. Pipe Dimensions (Geometrical Characteristics)

A. The pipe dimensions for water systems shall be based on standard dimensions
according to ISO 4427 and measured in accordance with ISO 3126.

B. Straight pipe shall be supplied in standard lengths measured at 23º C +/- 2º C.

unless otherwise specified, coil lengths shall not exceed 100 m.

C. Coiled pipes shall be coiled such that localized deformation is voided and the
minimum internal diameter of the coil shall not be less than 18 Dn.

20.2.1.4. Pipe Appearance

A. When viewed without magnification the internal and external surfaces of pipes
shall be smooth, clean and free from scoring, cavities and other surface defects.
The pipe ends shall be cut cleanly and square to the axis of the pipe.

B. The carbon black content in the compound shall be 2.25 + 0.25 % by mass when
measured in accordance with ISO 6964. The dispersion of carbon black when
determined in accordance with ISO 11420 shall be equal to or less than grade 3.

20.2.1.5. Fittings
A. Only fittings supplied or recommended by the pipe manufacturer and approved
by the Engineer shall be used. Fittings shall be installed in accordance with the
approved method statement.

B. The fittings shall be injection molded or formed from material compatible to that
of the pipe and shall be as resistant to the external and internal environments as
the other demands' of the pipe system.

C. At locations where HDPE to metal connections are specified, Nylon based

polyamide 11 coating system complying with the requirement of AWWC224 or
epoxy coated backing rings shall be used, or special restrained transition fittings
subject to approval by Client/End users/ENGINEER. The flanges shall be drilled
to ISO 7005-2, as per the design requirements.

20.2.1.6. Fittings Appearance

A. When viewed without magnification the internal and external surfaces of fittings
shall be smooth, clean and free from scoring, cavities and other surface defects.
The fitting shall be blue or black.

20.2.1.7. Fittings Dimensions

A The dimensions shall be measured in accordance with EN/ISO 3126

20.2.1.8. Wall Thickness of Fittings

A The wall thickness of the body of the fitting at any point shall be equal to or
greater than the minimum wall thickness of the corresponding pipe.
B The properties of the polymer, extruded pipe and fittings shall be as shown in
Tables 2.1.1, 2.1.2, and 2.1.3 below.

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Table 20.2-1: HDPE Resin Properties

Property Required Value Test Method Test Method

European ASTM
3
Density >940kg/m ISO 1183-3 D1505

Melt mass flow index or 0.2 to 1.4g/10min* ISO 1133 D1238 4

rate (2.16) condition 4

Melt mass flow index or 0.2 to 1.4g/10min* ISO 1133 D1238 5

rate (5.00) condition T

Melt mass flow index or >8g/10min ISO 1133 D1238 6

rate (21.6) condition G

Environmental stress >250hrs BS EN ISO D1693

crack resistance (10% 20088
stabilizer)

Resistance to internal >165hrs ISO 4427 DIN -

pressure 8047

Oxidation induction time >20mins BS EN 728 -

0
(200 C

Flexural creep modulus >900MPa - D790

0
Shore D hardness (40 C >50 - D2240

Tensile strength at yield >20MPa ISO 527 D638

(50mm/min

Elongation at break >600% ISO 527 -

Modulus of elasticity >1000MPa - -

Chirpy impact No break - -

0
Vicat softening point >125 C BS EN 727 -

0
Thermal expansion (20- <0.20mm/m/ C - -
0
90 C

Thermal conductivity <0.6W/mk - -

0
(20 C

Carbon black content >2.4 ISO 6964

Carbon black dispersion ISO 18533

*- Maximum deviation of +/- 20% of the nominated value

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Table 20.2-2: HDPE Pipe Properties

Property Required Value Test Method Test Method

European ASTM
3
Density >940 kg/m ISO 1183-3 D1505

Melt mass flow index or 0.2 to 1.4/10min* ISO 1133 D1238 5

0
rate (5.00kg, 190 C condition 1T

Oven test Defects shall not ISO 12091 -

develop

Resistance to internal No failure or defects ISO 1167 ISO -

0
pressure (20 C, water in 4427
water, hoop stress
1
12.4MPa, 100hrs)

Resistance to internal No failure or defects ISO 1167 ISO -

0
pressure (80 C, water in 4427
water, hoop stress
1
5.5MPa, 165hrs)

Resistance to internal No failure or defects ISO 1167 ISO -

0
pressure (80 C, water in 4427
water, hoop stress
1
5.0MPa, 1000hrs)

Creep ratio >900MPa BS EN ISO 9967 -

Longitudinal reversion <3% ISO 2505 -

0
(100 C

Shore D hardness >50 - D2240

Tensile strength at yield >20MPa ISO 527 D638

50mm/min

Elongation at break >350% ISO 527 -

Ring flexibility Refer standard BS EN 1446 -

Impact strength TIR 10% BS EN 744 -

Ring stiffness To SN or SD required BS EN ISO 9969 -

Quality Grade N ISO 11922

0
Thermal stability (200 C 20mins BS EN 728 -

Notch test (at 500 hours) Refer Standard ISO 13479

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Legend to Table 20.2-2

1) Either on pipe or from sample pipe using same resin and process.
*- Change of MFR by processing +/- 20% of the compound value

Table 20.2-3: HDPE Injection Molded Fittings Properties

Test Method Test Method

Property Required Value
European ASTM
3
Density >940kg/m ISO 1183-3 D1505

Melt mass flow index or rate 0.2 to ISO 1133 condition

0 D1238
(5.00kg, 190 C 1.4g/10min* 1T

Stiffness As required ISO 13967 -

Impact Refer standard BS EN 12061 -

Mechanical strength or
Refer standard BS EN 12256
flexibility
0
Thermal stability (200 C >20 mins BS EN 728 -

Resistance to internal pressure

0
(80 C, water in water, hoop No failure ISO 1167 ISO 4427 -
1
stress 5.5MPa, 165hrs)

Resistance to internal pressure

0
(80 C, water in water, hoop No failure ISO 1167 ISO 4427 -
1
stress 5.0MPa, 1000hrs)

Water tightness No leakage EN 1053 -

Legend to Table 20.2-3

1) For mounded materials use either an injection mounded or extruded pipe from
same materials.
*- Change of MFR by processing +/- 20% of the compound value

20.2.2 Quality Control Tests

A. The routine factory quality control tests listed below shall be carried out at the
required frequencies and records of all tests and inspections shall be maintained
by the manufacturer. The Engineer shall be provided with two copies of all test
certificates and reports.

i. Quality testing of all raw materials to ensure that they comply with the
relevant specification.
ii. Control of processing parameters in terms of temperature, pressure, flow
rates, haul-off speed and energy input.

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iii. Visual inspection of the pipes to check general appearance, dimensional

compliance and any indication of inclusions or processing flows in pipe
barrels and joining ends.
iv. Production short-term tests to identify any variations in the plant
functioning.
v. The following tests shall be performed in accordance with the
vi. Relevant standards in order to ensure the quality of the extruded pipes:

Melt mass-flow rate of raw material.

Density of raw material.
Carbon black content.
Carbon black dispersion.
Long-term stress crack resistance at 80°C.
Long-term MRS at 20°C on the raw material (data not older than 24
months)
Appearance.
Long term hydrostatic test at 20°C. (100hrs test)
Welding.
Slow tear test
Oxidation induction time value.
Visual inspection of pipes.
Dimensional check of pipes.
Heat reversion of pipes.
Hydrostatic creep strength tests of pipes.
Bend test / reverse bend test

B. When conditioning is required for laboratory tests, condition the specimens in

accordance with the appropriate standard.

C. Tensile testing for pipe resin, pipes and welds shall be performed on an
approved densitometer capable of delivering safely and accurately 120 % of the
stress required by the sample. The densitometer shall be connected to a
computerized system capable of delivering information in data and graphical
form. The information required from tensile measurements are tensile strength at
yield and peak and elongation at yield and peak.

i. Test specimens shall be milled to exact size using approved designated

milling machines. Each specimen shall be measured to an accuracy of 10
microns
ii. The Contractor shall submit statistical analysis based on minimum sample
populations of 32. Cumulative analysis based on overall and on individual
pipe resin batch based data shall also be provided.
iii. Welded samples shall be visually examined after tensile testing for signs of
adequate bonding and ductile and brittle failure. Weld samples with
greater than 25 % brittle failure shall be rejected.
iv. Tensile graphs indicating brittle failure shall be considered as failures.

D. The selection of samples of pipe, resin and welds for testing shall be as directed
by the Engineer.

E. If the results of any test fail to meet the requirements of this specification, the test
shall be repeated once again. If, upon retest, failure occurs, the batch quantity of
product represented by the test shall be rejected.

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F. The Contractor shall conduct quality checks at the manufacturer's premises to

ensure that the in-process manufacturing quality checks are being conducted
correctly and at the stated frequency. Test certificates relating to the batch shall
be furnished to the Engineer before acceptance of the delivery. The test
certificates shall contain all the details in the agreed format of reporting.

G. Marking shall be applied to the pipe in such a manner that it is legible after
installation and durable throughout the construction period. Each standard and
random length of pipe and every fitting shall be marked before dispatch from the
pipe manu

i.
ii. The dimensions nominal outside diameter X nominal wall thickness.
iii. The outside diameter tolerance.
iv. The designation of the pipe material.
v. The nominal pressure.
vi. The pipe series.
vii. The date of manufacture and batch number.
viii. Stencil in legible letters the pipe identification number on the inside and
outside at each end. Ensure that the same number appears on all record
sheets and documents relating to the manufacture, delivery and testing of
that pipe.
ix. The manufacturing standard.

20.3. Part 3 Execution

20.3.1 Pipe Installation
A. Trench excavation shall be carried out in accordance with Section 02225 of the
specification.

B. Install pipe, fittings, and accessories in accordance with manufacturer's

instructions.

i. Provide qualification details of the manufacturer's technical expert to be

assigned to the Contract. The technical expert shall have expertise,
experience and skills necessary for advising and monitoring all aspects of
transport, storage, handling, installation and testing of pipes as
appropriate.
ii. The technical expert shall provide comprehensive technical assistance to
the Contractor throughout the Contract and regularly monitor the
Contractor's activities and report on shortcomings.
iii. The Contractor shall provide the Engineer and DMAT copies of all
instructions advice or reports given by the manufacturer's technical expert
to him. The technical expert shall immediately inform the Engineer and
DMAT of any omission, variations and detractions from the specification.

C. The pipeline shall be within 20mm of the specified line and the invert level shall
be within 6mm of the specified value and shall be such that there is no back fall
at any point on a gravity pipeline.

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