SECTION F : HIGH DENSITY POLYETHYLENE (HDPE) …

1 SYABAS STANDARD specification FOR PIPE LAYING WOKS First Edition : May 2007 FF:: HHIIGGHH DDEENNSSIITTYY PPOOLLYYEETTHHYYLLEENNEE ((HHDDPPEE)) PPIIPPEESS AANNDD FFIITTTTIINNGGSS GENERAL This specification is applicable to high DENSITY POLYETHYLENE (HDPE) Pipe for water supply systems and shall conform to JKR Standard specification JKR 202000-0053-99 and MS 1058:2002. Relevant standards are:- BS 4505 specification for flanges and bolting for pipes, valves & fittings. Metric series. BS EN 545 DI pipes, fittings, accessories & their joints for water pipelines Requirements & test methods BS 970 Pt. 1 General Inspection and Testing Procedures and Specified requirements for Stainless Steel. AS 1646 Standard specification for Elastomeric joint rings for Waterworks purposes. MS 672:99 specification for rubber seals in water supply, drainage, & sewerage pipelines.

2 BS 5292 Jointing materials & components for installation using water, low pressure steam. BS 2789 specification for Iron castings with spheroidal nodular graphite. BS EN 1563 specification for Founding Spheriodal graphite cast iron. BS EN 10025 Hot rolled products of non-alloy structural steels and their Technical delivery conditions. BS 3643 ISO metric screw threads. BS 4190 ISO metric black hexagon bolts, screws and nuts. BS 6681 specification for Malleable cast iron. BS 6920 specification for Suitability of non-metallic products for use in contact with water intended for human consumption to their effect on the quality of the water. AS/NZS 4158 Thermal-bonded polymeric coatings on values and fitting for water industry purposes Liquid Epoxy Coating Systems For The Interior And Exterior Of Steel Water Pipelines. WIS 4-52-03 Water Industry specification for anti-corrosion coatings on threaded fasteners D:\TECHNICAL DEPARTMENT\SPEC YHH\New Folder\F- high SYABAS STANDARD specification FOR PIPE LAYING WOKS First Edition : May 2007 ISO 12162 Thermoplastics materials for pipes and fitting for pressure applications Classification and designation overall service ( design ) coefficient.

3 ISO 12176-1:98 Plastics pipes and fittings Equipment for fusion jointing POLYETHYLENE systems Part 1 : Butt Fusion. EN 712 Thermoplastics piping system End load bearing mechanical joints between pressure pipes and fittings Test method for resistance to pull out under constant longitudinal force. EN 713 Plastics piping system Mechanical joints between fittings and polyolefin pressure pipes Test method for leak tightness under internal pressure whilst subjected to bending. EN 715 Thermoplastics piping systems Mechanical and cemented joints between pressure pipes and fittings Test method for leak tightness under internal pressure, including end thrust. EN 921 Thermoplastics pipes Determination of resistance to internal pressure at constant temperature. ISO 13953:1995 POLYETHYLENE pipes and fittings Determination of tensile strength of test piece from butt fused joint.

4 ISO 13954:1997 Plastics pipes and fittings Peel de-cohesion test for POLYETHYLENE (PE) electro-fusion assemblies of nominal outside diameter greater than or equal to 90mm. ISO 13955:1997 Plastics pipes and fittings Crushing de-cohesion test for POLYETHYLENE (PE) electro-fusion assemblies. ISO 13956:1995 Plastics pipes and fittings Pull out de-cohesion test for POLYETHYLENE electro-fusion assemblies. MATERIAL The high DENSITY POLYETHYLENE (HDPE) Pipe shall be made from base polymer and shall conform to the requirements as specified in MS 1058 Part 1:2002. The base polymer shall be a single grade of POLYETHYLENE , PE 80 with a derived DENSITY greater than tested at 20 C. No rework material is allowable for the manufacture of the pipes. No additives that may contribute to toxic hazard, impair the fabrication of properties and chemical and physical properties in particular to long term mechanical and strength is allowed.

5 COLOUR D:\TECHNICAL DEPARTMENT\SPEC YHH\New Folder\F- high SYABAS STANDARD specification FOR PIPE LAYING WOKS First Edition : May 2007 The colour of the pipes shall be black with blue stripes. The material for stripes shall be of the same type of resin as used in the compound for the pipe. PIPE CLASSIFICATION AND DIMENSION All HDPE Pipes must be from Class PE 80 with Nominal Pressure (PN) and Standard Dimensions Ratio (SDR) 11 with the minimum strength at 20 C. Wall thickness and nominal diameter of PE 80 pipes are given below. NOM. DIAMETER FOR OTHER PIPES (mm) WALL THICKNESS (mm) INTERNAL DIAMETER (mm) OUTSIDE DIAMETER (mm) 20 18 20 25 25 32 29 32 40 40 50 50 63 63 75 75 90

6 90 110 100 110 125 125 140 140 160 160 180 180 200 200 225 225 250 250 280 280 315 315 355 355 400 400 450 450 500 500 560 630

7 D:\TECHNICAL DEPARTMENT\SPEC YHH\New Folder\F- high SYABAS STANDARD specification FOR PIPE LAYING WOKS First Edition : May 2007 TOLERANCE The tolerance for wall thickness is determined by the difference between the wall thickness and the nominal wall thickness as follow: PN PN 16 NOM. DIAMETER FOR OTHER PIPES (mm) WALL THICKNESS (mm) Min WALL THICKNESS (mm) Max WALL THICKNESS (mm) Min WALL THICKNESS (mm) Max 20 25 32 40 50 63 75

8 90 110 125 140 160 180 200 225 250 280 315 355 400 450 500 560

9 56 630 LENGTH The required length of HDPE pipes in coil for nominal diameter 63 mm and below will be100 meter. The standard length of HDPE pipes for nominal diameter 125 mm and above shall be 9m or 12m. APPEARANCE The internal and external surfaces of pipes must smooth, clean and free from scoring, cavities and other surface defects which may affect pipe performance. The ends of pipe shall cut cleanly and square to the axis of the pipe. Appearance shall be checked at the point of manufacture. D:\TECHNICAL DEPARTMENT\SPEC YHH\New Folder\F- high SYABAS STANDARD specification FOR PIPE LAYING WOKS First Edition : May 2007 ROUTINE TESTS The pipe suppliers shall, as and when requested by the , furnish results of the routine tests carried out in accordance with the requirements as stipulated in MS 1058: Part 1 : 2002.

10 The minimum Oxidation Induction Time (OIT) for pipes fitting shall be 80 min. The manufacturer must have their own differential Thermal Analyzer or Differential Scanning Calorimeter available for SYABAS representatives to carry out the OIT. PIPE MARKINGS All pipes must have the following markings: Manufacturer s name or trade mark Dimensions Material supplier and material class (PE 80) Pipe Class (PN) The word SYABAS (50mm high ) in capital letter SIRIM/IKRAM and QAS Number. Year of manufacture (last two digits) Batch production number PIPE FITTINGS Types of pipe fittings The following types fittings shall comply to MS 1058 or EN 12201 3 a) Spigot fittings b) Electro-fusion fittings and c) Mechanical fittings and joints Spigot Fittings Spigot fittings fall under three classes as shown below. Class Description Moulded Injection moulded fittings Fabricated Fitting which are assembled using butt fusion joints o PE 80 min.