Dimension of HDPE Pipes
for Material Grade PE-63 as per IS 4984 : 1995
All Dimensions in
Millimeters
|
WALL THICKNESS OF PIPES FOR PRESSURE RATINGS OF |
|||||||||||||||
|
Nominal
Dia |
PN 2.5 |
PN 4 |
PN 6 |
PN 8 |
PN 10 |
PN 12.5 |
PN 16 |
||||||||
|
DN |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
|
|
(1) |
(2) |
(3) |
(4) |
(5) |
(6) |
(7) |
;(8) |
(9) |
(10) |
(11) |
(12) |
(13) |
(14) |
(15) |
|
|
20 |
- |
- |
- |
- |
- |
- |
- |
- |
2.3 |
2.8 |
2.8 |
3.3 |
3.4 |
4.0 |
|
|
25 |
- |
- |
- |
- |
- |
- |
2.3 |
2.8 |
2.8 |
3.3 |
3.4 |
4.0 |
4.2 |
4.9 |
|
|
32 |
- |
- |
- |
- |
2.3 |
2.8 |
3.0 |
3.5 |
3.6 |
4.2 |
4.4 |
5.1 |
5.4 |
6.2 |
|
|
40 |
- |
- |
2.0 |
2.4 |
2.8 |
3.3 |
3.7 |
4.3 |
4.5 |
5.2 |
5.5 |
6.3 |
6.7 |
7.6 |
|
|
50 |
- |
- |
2.4 |
2.9 |
3.5 |
4.1 |
4.6 |
5.3 |
5.6 |
6.4 |
6.8 |
7.7 |
8.4 |
9.5 |
|
|
63 |
2.0 |
2.4 |
3.0 |
3.5 |
4.4 |
5.1 |
5.8 |
6.6 |
7.0 |
7.9 |
8.6 |
9.7 |
10.5 |
11.8 |
|
|
75 |
2.3 |
2.8 |
3.6 |
4.2 |
5.3 |
6.1 |
6.9 |
7.8 |
8.4 |
9.5 |
10.2 |
11.5 |
12.5 |
14.0 |
|
|
90 |
2.8 |
3.3 |
4.3 |
5.0 |
6.3 |
7.2 |
8.2 |
9.3 |
10.0 |
11.2 |
12.2 |
13.7 |
15.0 |
16.7 |
|
|
110 |
3.4 |
4.0 |
5.3 |
6.1 |
7.7 |
8.7 |
10.0 |
11.2 |
12.3 |
13.8 |
14.9 |
16.6 |
18.4 |
20.5 |
|
|
125 |
3.8 |
4.4 |
6.0 |
6.8 |
8.8 |
9.9 |
11.4 |
12.8 |
13.9 |
15.5 |
16.9 |
18.8 |
20.9 |
23.2 |
|
|
140 |
4.3 |
5.0 |
6.7 |
7.6 |
9.8 |
11.0 |
12.8 |
14.3 |
15.6 |
17.4 |
19.0 |
21.1 |
23.4 |
26.0 |
|
|
160 |
4.9 |
5.6 |
7.7 |
8.7 |
11.2 |
12.6 |
14.6 |
16.3 |
17.8 |
19.8 |
21.7 |
24.1 |
26.7 |
29.6 |
|
|
180 |
5.5 |
6.3 |
8.6 |
9.7 |
12.6 |
14.1 |
16.4 |
18.3 |
20.0 |
22.2 |
24.4 |
27.1 |
30.0 |
33.2 |
|
|
200 |
6.0 |
7.0 |
9.6 |
10.8 |
14.0 |
15.6 |
18.2 |
20.3 |
22.3 |
24.8 |
27.1 |
30.1 |
33.4 |
37.0 |
|
|
225 |
6.0 |
7.8 |
10.8 |
12.1 |
15.7 |
17.5 |
20.5 |
22.8 |
25.0 |
27.7 |
30.5 |
33.8 |
37.5 |
41.5 |
|
|
250 |
7.6 |
8.6 |
12.0 |
13.4 |
17.5 |
19.5 |
22.8 |
25.3 |
27.8 |
30.8 |
33.8 |
37.4 |
41.7 |
46.1 |
|
|
280 |
8.5 |
9.6 |
13.4 |
15.0 |
19.6 |
21.8 |
25.5 |
28.3 |
31.2 |
34.6 |
37.9 |
41.9 |
46.7 |
51.6 |
|
|
315 |
9.6 |
10.8 |
15.0 |
16.7 |
22.0 |
24.4 |
28.7 |
31.8 |
35.0 |
38.7 |
42.6 |
47.1 |
52.5 |
58.0 |
|
|
355 |
10.8 |
12.1 |
17.0 |
18.9 |
24.8 |
27.5 |
32.3 |
35.8 |
39.5 |
43.7 |
48.0 |
53.0 |
59.2 |
65.4 |
|
|
400 |
12.2 |
14.3 |
19.1 |
22.2 |
28.0 |
32.4 |
36.4 |
42.1 |
44.5 |
51.4 |
54.1 |
62.5 |
- |
- |
|
|
450 |
13.7 |
16.0 |
21.5 |
25.0 |
31.4 |
36.4 |
41.0 |
47.4 |
50.0 |
57.7 |
- |
- |
- |
- |
|
|
500 |
15.2 |
17.7 |
23.9 |
27.7 |
34.9 |
40.4 |
45.5 |
52.6 |
55.6 |
64.2 |
- |
- |
- |
- |
|
|
560 |
17.0 |
19.8 |
26.7 |
31.0 |
39.1 |
45.2 |
51.0 |
58.9 |
- |
- |
- |
- |
- |
- |
|
|
630 |
19.1 |
22.2 |
30.0 |
34.7 |
44.0 |
50.8 |
57.3 |
66.1 |
- |
- |
- |
- |
- |
- |
|
|
710 |
21.6 |
25.1 |
33.9 |
39.2 |
49.6 |
57.3 |
- |
- |
- |
- |
- |
- |
- |
- |
|
|
800 |
24.3 |
28.2 |
38.1 |
44.1 |
55.9 |
64.5 |
- |
- |
- |
- |
- |
- |
- |
- |
|
|
900 |
27.3 |
31.6 |
42.9 |
49.6 |
- |
- |
- |
- |
- |
- |
- |
- |
- |
- |
|
|
1000 |
30.4 |
35.2 |
47.7 |
55.1 |
- |
- |
- |
- |
- |
- |
- |
- |
- |
- |
|
Dimension of HDPE Pipes for Material Grade PE-80 as per IS 4984 : 1995
|
WALL THICKNESS OF PIPES FOR PRESSURE RATINGS OF |
|||||||||||||||
|
Nominal Dia |
PN 2.5 |
PN 4 |
PN 6 |
PN 8 |
PN 10 |
PN 12.5 |
PN 16 |
||||||||
|
DN |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
|
|
(1) |
(2) |
(3) |
(4) |
(5) |
(6) |
(7) |
(8) |
(9) |
(10) |
(11) |
(12) |
(13) |
(14) |
(15) |
|
|
20 |
- |
- |
- |
- |
- |
- |
- |
- |
- |
- |
2.3 |
2.8 |
2.8 |
3.3 |
|
|
25 |
- |
- |
- |
- |
- |
- |
- |
- |
2.3 |
2.8 |
2.8 |
3.3 |
3.5 |
4.1 |
|
|
32 |
- |
- |
- |
- |
- |
- |
2.4 |
2.9 |
3.0 |
3.5 |
3.6 |
4.2 |
4.5 |
5.2 |
|
|
40 |
- |
- |
- |
- |
2.3 |
2.8 |
3.0 |
3.5 |
3.7 |
4.3 |
4.5 |
5.2 |
5.6 |
6.4 |
|
|
50 |
- |
- |
2.3 |
2.8 |
2.9 |
3.5 |
3.8 |
4.4 |
4.4 |
5.3 |
5.6 |
6.4 |
6.9 |
7.5 |
|
|
63 |
- |
- |
2.5 |
3.0 |
3.6 |
4.2 |
4.7 |
5.4 |
5.3 |
6.6 |
7.0 |
7.9 |
8.7 |
9.8 |
|
|
75 |
- |
- |
2.9 |
3.4 |
4.3 |
5.0 |
5.6 |
6.4 |
6.3 |
7.8 |
8.4 |
9.5 |
10.4 |
11.7 |
|
|
90 |
2.3 |
2.8 |
3.5 |
4.1 |
5.1 |
5.9 |
6.7 |
7.6 |
8.2 |
9.3 |
10.0 |
11.2 |
12.5 |
14.0 |
|
|
110 |
2.7 |
3.2 |
4.3 |
5.0 |
6.3 |
7.2 |
8.2 |
9.3 |
10.0 |
11.2 |
12.3 |
13.8 |
15.2 |
17.0 |
|
|
125 |
3.1 |
3.7 |
4.9 |
5.6 |
7.1 |
8.1 |
9.3 |
10.5 |
11.4 |
12.8 |
13.9 |
15.5 |
17.3 |
19.3 |
|
|
140 |
3.5 |
4.1 |
5.4 |
6.2 |
8.0 |
7.0 |
10.4 |
11.7 |
12.8 |
14.3 |
15.6 |
17.4 |
19.4 |
21.6 |
|
|
160 |
4.0 |
4.6 |
6.2 |
7.1 |
9.1 |
10.3 |
11.9 |
13.3 |
14.5 |
16.3 |
17.8 |
19.8 |
22.1 |
24.6 |
|
|
180 |
4.4 |
5.1 |
7.0 |
7.9 |
10.2 |
11.5 |
13.4 |
15.0 |
16.4 |
18.3 |
20.0 |
22.2 |
24.9 |
27.6 |
|
|
200 |
4.9 |
5.6 |
7.7 |
8.7 |
11.4 |
12.8 |
14.9 |
16.6 |
18.0 |
20.3 |
22.3 |
24.8 |
27.6 |
30.6 |
|
|
225 |
5.5 |
6.3 |
8.7 |
9.8 |
12.8 |
14.4 |
16.7 |
18.6 |
20.0 |
22.8 |
25.0 |
27.7 |
31.1 |
34.5 |
|
|
250 |
6.1 |
7.0 |
9.7 |
10.9 |
14.2 |
16.9 |
18.6 |
20.7 |
22.0 |
25.3 |
27.8 |
30.6 |
34.5 |
38.2 |
|
|
280 |
6.9 |
7.8 |
10.8 |
12.1 |
15.9 |
17.7 |
20.8 |
23.1 |
25.5 |
28.3 |
31.2 |
34.6 |
38.7 |
42.8 |
|
|
315 |
7.7 |
8.7 |
12.2 |
13.7 |
17.9 |
19.9 |
23.4 |
26.0 |
28.7 |
31.8 |
35.0 |
38.7 |
43.5 |
48.1 |
|
|
355 |
8.7 |
9.8 |
13.7 |
15.3 |
20.1 |
22.4 |
26.3 |
29.2 |
32.3 |
35.8 |
39.5 |
43.7 |
49.0 |
54.1 |
|
|
400 |
9.8 |
11.5 |
15.4 |
18.0 |
22.7 |
26.4 |
29.7 |
34.4 |
36.4 |
42.1 |
44.5 |
51.4 |
55.2 |
63.7 |
|
|
450 |
11.0 |
12.9 |
17.4 |
20.3 |
25.5 |
29.6 |
33.4 |
38.7 |
44.0 |
47.4 |
50.0 |
57.7 |
- |
- |
|
|
500 |
12.2 |
14.3 |
19.3 |
22.4 |
28.4 |
32.9 |
37.1 |
42.9 |
45.5 |
52.6 |
55.6 |
64.2 |
- |
- |
|
|
560 |
13.7 |
16.0 |
21.6 |
25.1 |
31.7 |
36.7 |
41.5 |
48.0 |
51.0 |
58.9 |
- |
- |
- |
- |
|
|
630 |
15.4 |
18.0 |
24.3 |
28.2 |
35.7 |
41.3 |
46.7 |
54.0 |
57.3 |
66.1 |
- |
- |
- |
- |
|
|
710 |
17.4 |
20.3 |
27.4 |
31.8 |
40.2 |
46.5 |
52.6 |
60.7 |
- |
- |
- |
- |
- |
- |
|
|
800 |
19.6 |
22.8 |
30.8 |
35.7 |
45.3 |
52.3 |
- |
- |
- |
- |
- |
- |
- |
- |
|
|
900 |
22.0 |
25.5 |
34.7 |
40.2 |
51.0 |
58.9 |
- |
- |
- |
- |
- |
- |
- |
- |
|
|
1000 |
24.4 |
28.3 |
38.5 |
44.5 |
56.7 |
65.5 |
- |
- |
- |
- |
- |
- |
- |
- |
|
Dimension of HDPE Pipes for Material Grade PE-100 as per IS 4984 : 1995
|
Wall Thickness of Pipes for Pressure Rating of |
|
||||||||||
|
Nominal Dia |
PN 6 |
PN 8 |
PN 10 |
PN 12.5 |
PN 16 |
||||||
|
DN |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
Min. |
Max. |
|
|
(1) |
(2) |
(3) |
(4) |
(5) |
(6) |
(7) |
(8) |
(9) |
(10) |
(11) |
|
|
20 |
- |
- |
- |
- |
- |
- |
- |
- |
2.3 |
2.8 |
|
|
25 |
- |
- |
- |
- |
- |
- |
2.3 |
2.8 |
2.9 |
3.4 |
|
|
32 |
- |
- |
- |
- |
2.4 |
2.9 |
2.9 |
3.4 |
3.7 |
4.3 |
|
|
40 |
- |
- |
2.4 |
2.9 |
3.0 |
3.5 |
3.7 |
4.3 |
4.6 |
5.3 |
|
|
50 |
2.3 |
2.8 |
3.0 |
3.5 |
3.7 |
4.3 |
4.6 |
5.3 |
5.7 |
6.5 |
|
|
63 |
2.9 |
3.4 |
3.8 |
4.4 |
4.7 |
5.4 |
5.7 |
6.5 |
7.1 |
8.1 |
|
|
75 |
3.5 |
4.1 |
4.5 |
5.2 |
5.6 |
6.4 |
6.8 |
7.7 |
8.5 |
9.6 |
|
|
90 |
4.1 |
4.8 |
5.4 |
6.2 |
6.7 |
7.6 |
8.2 |
9.3 |
10.2 |
11.5 |
|
|
110 |
5.0 |
5.7 |
6.6 |
7.5 |
8.1 |
9.2 |
10.0 |
11.2 |
12.4 |
13.9 |
|
|
125 |
5.7 |
6.5 |
7.5 |
8.5 |
9.2 |
10.4 |
11.3 |
12.7 |
14.1 |
15.8 |
|
|
140 |
6.4 |
7.3 |
8.4 |
9.5 |
10.3 |
11.6 |
12.7 |
14.2 |
15.8 |
17.6 |
|
|
160 |
7.3 |
8.3 |
9.6 |
10.8 |
11.8 |
13.2 |
14.5 |
16.2 |
18.1 |
20.2 |
|
|
180 |
8.2 |
9.3 |
10.8 |
12.1 |
13.3 |
14.9 |
16.3 |
18.2 |
20.3 |
22.6 |
|
|
200 |
9.1 |
10.3 |
12.0 |
13.4 |
14.8 |
16.5 |
18.1 |
20.2 |
22.6 |
25.1 |
|
|
225 |
10.3 |
11.6 |
13.5 |
15.1 |
16.6 |
18.5 |
20.4 |
22.7 |
25.4 |
28.2 |
|
|
250 |
11.4 |
12.8 |
15.0 |
16.7 |
18.4 |
20.5 |
22.6 |
25.1 |
28.2 |
31.3 |
|
|
280 |
12.8 |
14.3 |
16.8 |
18.7 |
20.6 |
22.9 |
25.3 |
28.1 |
31.6 |
35.0 |
|
|
315 |
14.4 |
16.1 |
18.9 |
21.0 |
23.2 |
25.8 |
28.5 |
31.6 |
35.5 |
39.3 |
|
|
355 |
16.2 |
18.1 |
21.2 |
23.6 |
26.2 |
29.1 |
32.1 |
35.6 |
40.0 |
44.2 |
|
|
400 |
18.2 |
21.2 |
23.9 |
27.7 |
29.5 |
34.2 |
36.2 |
41.9 |
45.1 |
52.1 |
|
|
450 |
20.5 |
23.8 |
26.9 |
31.2 |
33.1 |
38.3 |
40.7 |
47.1 |
50.8 |
58.7 |
|
|
500 |
22.8 |
26.5 |
29.9 |
34.6 |
36.8 |
42.6 |
45.2 |
52.2 |
56.4 |
65.1 |
|
|
560 |
25.5 |
29.6 |
33.5 |
38.8 |
41.2 |
47.6 |
50.6 |
58.4 |
- |
- |
|
|
630 |
28.7 |
33.3 |
37.7 |
43.6 |
46.4 |
53.6 |
56.9 |
65.7 |
- |
- |
|
|
710 |
32.3 |
37.4 |
42.4 |
49.0 |
52.3 |
60.4 |
- |
- |
- |
- |
|
|
800 |
36.4 |
42.1 |
47.8 |
52.2 |
58.9 |
68.0 |
- |
- |
- |
- |
|
|
900 |
41.0 |
47.4 |
53.8 |
62.1 |
- |
- |
- |
- |
- |
- |
|
|
1000 |
45.5 |
52.6 |
- |
- |
- |
- |
- |
- |
- |
- |
|
7.4 INSTALLATION FOR HDPE PIPES:
7.4.1 BUTT WELDING : A
RELIABLE METHOD FOR LEAKPROOF JOINTS OF
HDPE PIPES:
BUTT WELDING is the most important
jointing method in HDPE pipes. This method is known as a heat pressure related
process by which the pipe end material of two pipes are melted together under
pressure creating a homogenous pipe structure. Simple in its idea, the butt
fusion process demands high accuracy to give the final product i.e. a BUTT
WELD. However, the method is very simple and reliable.
1. The two
pipes to be welded are clamped in a welding machine &
are brought in axial alignment.
2. Ends of pipes are cleaned using damp
cloth and scraper to ensure that welding faces are free from dust and other
foreign materials.
3. The pipe ends are pressurised against
the hot plate with a specified temperature (between 2000- 2100C),
pressure and specified time. The pipe material melts forming a circular bid on
periphery of both the pipe ends.
4. When the ends of pipes melted and bid formation is over,
the hot plate is removed and the melted ends are pressed against each other to
make a Butt Weld. The welding 4pressure is specified and welded time as well.
When the weld has been cooled down the pipes are taken out from the machine and
preparation of next joint can start.
AUTOMATIC AIR VENT (AAV):
Automatic air vents, shall
be furnished at the top of main water risers, supply and return pipes.
A shut-off valve shall be provided at the
inlet of each automatic air vent. The
outlet shall be piped to the nearest drain.
Air Release Valves shall
be capable of automatically releasing accumulated air from a fluid system while
that system is in operation and under pressure. To assure drop tight shut-off,
a viton orifice button shall be used to seal the valve discharge orifice when
the valve is in a closed position. The
orifice diameter will be sized for use within a given operating pressure range
to insure maximum discharge capacity.
9.0 DUCTILE IRON PIPES & FITTINGS
DI pipes (Class K9) and fittings (Class
12) shall be in accordance with IS 8329 and IS 9523 respectively. Pipes and
fittings shall be procured from reputed manufacturers. The Contractor
or their authorized representative shall
at all reasonable times have free access to the place where the pipes and
fittings are manufactured for the purpose of examining and testing the pipes
and fittings and for witnessing the test and manufacturing.
The pipes and fittings shall be stripped,
with all precautions necessary to avoid warping or shrinking defects. The pipes
and fittings shall be free from defects. In the case of spigot and socket pipes
and fittings the socket shall be without the centre ring.
In the case of flanged pipes, the flanges
shall be at the right angles to the axis of the pipe and machined on face. The
bolt holes shall be drilled and located symmetrically off the centre line. The
bolt holes shall be concentric with the bore and bolt holes equally spaced. The
flanges shall be integrally cast with the pipes and fittings and the two
flanges of the pipe shall be correctly aligned.
The materials used in the manufacture of pipes and fittings shall
comply with requirements specified in IS 8329 and IS 9523.
Dimensions and Tolerances
The internal diameter, thickness and length of barrel, dimensions of
pipes and fittings shall be as per relevant tables of IS 8329/IS 9523 for
different class of pipes and fittings. Each pipe shall be of uniform thickness
throughout its length.
The tolerances for pipes and fittings regarding dimensions,
mass, ovality and deviations from straight line in case of pipes shall be as
per IS 8329/IS 9523.
Testing
Mechanical Tests
Mechanical tests shall be carried out during manufacture of
pipes and fittings as specified in IS 8329 / IS 9523. The frequency and
sampling of tests for each batch of pipes shall be in accordance with IS 8329.
The test results so obtained for all the pipes and fittings of different sizes
shall be submitted to the Contractor or his authorized representative. The
method for tensile tests and the minimum tensile strength requirement for pipes
and fittings shall be as per IS 8329/IS 9523.
Brinell Hardness Test
For checking the Brinell hardness, the test shall be
carried out on the test ring or bars cut from the pipes used for the ring test
and tensile test in accordance with IS 1500. The test shall comply with the
requirements specified in IS 1500/IS 8329.
(a)
Retests
If any test piece representing a lot fails in the
first instance, two additional tests shall be made on test pieces selected from two other pipes
from the same lot. If both the test results satisfy the specified requirements,
the lot shall be accepted. Should either
of these additional test pieces fail to pass the test, the lot shall be liable
for rejection.
(b)
Hydrostatic Test
For hydrostatic test at works, the pipes and fittings
shall be kept under test pressure as specified in IS 8329 / IS 9523 for a
period of minimum 15 seconds, during which the pipes shall be struck moderately
with a 700 g hammer for conformation of satisfactory sound. They shall
withstand the pressure test without showing any leakage, sweating or other
defect of any kind. The hydrostatic test shall be conducted before surface
coating and lining.
·
General
Jointing of DI pipes and fittings shall be done as per
IS 12288 and manufacturer's recommendations. After jointing, extraneous
material, if any, shall be removed from the inside of the pipe. Rubber sealing
rings/gaskets used for jointing shall conform to IS 638, IS 12820 and IS 5382.
·
Spigot and Socket joints
These
shall have sockets which are integral with the pipe and incorporate an
elastomeric rubber ring gasket conforming to IS 12820.In particular that the
spigot end of the pipe shall be ensured to be jointed is smooth and has been
properly chamfered, so that the rubber ring as per IS 12820 and IS 5382 is
correctly positioned in line, before the joint is made. The rubber rings and any recommended
lubricant shall be obtained only through the pipe supplier.
·
Gaskets for Flanges
All
gaskets used between flanges of pipes shall be of Styrene Butadyne Rubber or
EPDM thickness 3 mm suitable for clear water conveyance and as specified by
manufacturer.
·
Flanged joints
These
shall be of PN 16 rating and shall comply with dimensions and drilling details
as specified in IS 8329. These shall have isolation gaskets between the
flanges, isolation sleeves around all bolts and isolation washers under all
bolt heads and nuts. All material shall be supplied by a reputed manufacturer.
Each bolt should be tightened a little at a time taking care to tighten
diametrically opposite bolts alternatively.
Coatings
(a)
General
Unless
otherwise specified, DI pipes and fittings shall be coated with Bitumen in
accordance with relevant IS specification.
All buried DI pipes and fittings shall also have factory or site applied
polythene sleeving. Coating shall not be
applied to pipe and fittings unless its surface is clean, dry and free from
rust. Pipe coatings shall be inspected
at site and any damage or defective areas shall be made good.
(b)
Coating
Bitumen
coating shall be of normal thickness of 75 microns unless otherwise
specified. It shall be cold applied
compound complying with the requirements of relevant Indian standards, suitable
for tropical climates, factory applied in accordance with the manufacturer's
instructions.
The outer
surface of the pipe shall have Zinc coating with finishing layer of Bitumen
over it as per IS 8329.
Damaged
areas of coating shall be repainted on site after removing any remaining loose
coating and wire brushing any rusted areas of pipe.
(c)
Cement mortar lining
All pipes and fittings shall be internally lined with cement mortar in accordance with IS: 8329. Cement mortar lining shall be applied at the factory in conformance with the above mentioned standards. Pipe linings shall be inspected on site and any damage or defective areas shall be made good. Lining shall be uniform in thickness all along the pipe. The minimum thickness of factory applied cement mortar lining shall be 3mm for up to DN 300 mm pipes.
(d) Marking
Marking
shall be done as per IS 8329 and IS 9523 or any other relevant IS codes.
10.0 STERILIZATION OF
INSTALLATION:
10.1 The water supply installation shall be sterilized as per standards
and as follows :-
a)
Tanks
and pipes shall be filled and flushed out.
b)
All
bib cocks (taps) shall be closed.
c)
Tanks
and pipes shall be re-filled while adding a sterilizing admixture containing 50
parts chlorine to one million parts water.
d)
When
the installation is filled all bib cocks (taps) shall be opened progressively
and each allowed to run until the water smells of chlorine.
e)
The
installation shall be topped up and more sterilizer added.
f)
The
installation shall then be left for three hours and shall then be tested for
residual chlorine, if none is found, the installation shall be drained and the
process repeated.
g)
The
installation shall be finally drained and flushed with potable water before
use.
D) EXTERNAL SEWERAGE & STORM WATER DRAINAGE:
1.0
Scope of Work:
1.1
Without restricting to the
generality of the foregoing, the drainage system shall interalia include:
a)
Sewerage/Storm water drainage system including,
earth works for excavation, disposal, backfilling and compaction, pipe lines,
manholes, catch basins and connections to Rain water Harvesting or connected as
indicated by the Architect/Consultants.
b) Overflow
from Rain Water Harvesting Pit shall be discharged to existing Storm Water
drain either by gravity or by submersible
drainage pump.
2.0 General
Requirements:
2.1 All
material shall be of the best quality conforming to specification and subject
to the approval of the Engineer-in-charge.
2.2 Storm
Water Drainage lines and open drains shall be laid to the required gradients
and profiles.
2.3 All
drainage work shall be done in accordance with the local municipal bye-laws.
2.4 Contractor
shall obtain necessary approval and permission for the drainage system from the
municipal or any other competent authority if required.
3.0 Excavation :
3.1 Alignment
and Grade:
The drains are to be laid to
alignment and gradients shown on the drawings but subject to such
modifications, as shall be ordered by the Construction Manager/Consultants
from time to time to meet the requirements of the works. No deviations from the
line, depths of cutting or gradients of sewers shown in the plans and sections
shall be permitted except by the express direction in writing of the
Construction Manager/Consultants.
3.2 Opening out Trenches:
In excavating the trenches at the road
metaling, pavement kerbing etc are to be placed on one side and preserved for
rein statement when the trench or other excavation shall be filled-up.
Before any road metal is replaced, it
shall be carefully shifted. The surface of all trenches and holes shall be
restored and maintained to the satisfaction of the Construction
Manager/Consultants. The contractor shall not cut or break down any live fence
or trees in the line of the proposed works but shall tunnel under them unless
the Construction Manager/Consultants shall order to the contrary.
The contractor shall scrub up and clear the surface over the trenches
and other excavations of all stumps, roots and all other encumbrances affecting
execution of the work and shall remove them from the site to the approval of
the Construction Manager/Consultants
3.3 Construction Across the Roads:
All works across the roads shall be carried out as per the directions of
the Construction Manager/Consultants.
3.4 Excavation to be taken to proper depth:
The trenches shall be excavated to such a depth that the sewers shall
rest as described earlier so that the inverts may be at the levels given on
the section/plan. If the strata found as slushy/with block cotton soil etc, the
Construction Manager/Consultants may order the contractor to excavate to a
greater depth than that shown on the drawings and to fill up the excavation to
the level of the sewer with such materials as decided by Construction
Manager/Consultants in writing.
3.5 Refilling:
After the sewer or other works have been laid and proved to be water
tight, the trench or other excavation shall be refilled. Utmost care shall be
taken in doing this, so that no damage is caused to the sewer and other
permanent works. Filling in the trenches upto 50 cms above the crown of the
sewer shall consist of the finest selected materials placed carefully in 15 cms
layers watered to optimum moisture level and consolidated. After this has been
laid, the trench and the other excavation shall be refilled carefully in 15 cms
layers with materials taken from the excavation, each layer being watered and
consolidated.
3.6 Contractor shall restore settlement
and damages:
The contractor shall at his own cost make good promptly during the whole
period the works are in hand, any settlements that may occur in the surfaces
or roads, beams, footpaths, gardens, open spaces etc. Whether public or private
caused by his trenches or by his other excavations and he shall be liable for
any accidents caused thereby.
He shall also at his own expense and charges, repair and make good any
damage done to the building and other properties.
3.7 Disposal of Surplus Soil:
The contractor shall at his own cost and charge, dispose off from the
site all surplus excavated material not required to be used on the works.
3.8 Timbering of Sewer and Trenches:
The contractor shall at all times support efficiently and effectively
the sides of the sewer trenches and other excavations by suitable timbering.
piling, sheeting, etc in loose or sandy strata and below the surface of the sub
soil water table without extra cost.
All timbering, sheeting and piling with their walls and supports shall
be of adequate dimensions and strengths and fully broad and strutted so that
there is no risk of collapse or carrying in the walls of the trench.
The Contractor shall be held accountable and responsible for the
sufficiency of all timbering, bracing, sheeting and piling used, and for all
damage to persons and property resulting from the improper quality, strength,
planning, maintaining or removing of the same.
3.9 WIDTH OF TRENCH :
a) Recommended width of trenches at the
bottom shall be as follows
or as specified in the CPWD
/BIS specification :-
100mm dia pipe Outer
dia of pipe + 45cms
150mm dia pipe Outer
dia of pipe + 45cms
200-250 dia pipe Outer
dia of pipe + 45cms
300mm dia pipe Outer
dia of pipe + 45cms
450mm dia pipe & above outer dia of pipe +45cms
b) Recommended width of trench at top shall be as follows or as specified in the CPWD /BIS
specification :-
Depth up to 1.5m - width of Bottom = width of top
Depth from 1.5m to 3m - Bottom width + (2X500mm)
Depth From 3m to 4.5 m - Bottom width +(4X500mm)
Depth From 4.5m to 6.0 m - Bottom width + (6X500mm)
3.10 Protection of Existing Services:
All pipes, water mains, cables etc encountered in the course of
excavation shall be carefully protected and supported.
4.0 SALT GLAZED STONEWARE
PIPES :
4.1 Stoneware pipes shall
be of first class quality salt glazed and free from rough texture, inside and outside
and straight. All pipes shall have the manufacturers name marked on it and
shall comply to IS : 651-1971.
4.2 Laying:
The pipes shall be carefully laid to the levels and gradients shown on
the plans and sections.
4.3 Jointing:
Hemp rope soaked in neat cement wash shall be passed round the joint and
inserted in it by means of caulking tool. More skein of yarn shall be added and
rammed home. Cement mortar with one part of cement and one part of sand and
with minimum water content but on no account soft or sloppy, shall be carefully
inserted, punched and caulked into the joint and more cement mortar added until
the space of the joint has been filled completely with tightly caulked mortar.
The joint shall then be finished off neatly outside the socket at an angle of
45 degree.
4.4 Curing:
The joint shall be cured for at
least seven days.
4.5 Testing:
All lengths of the sewer and drain shall be fully tested for water
tightness by means of water pressure maintained for not less than 30 minutes.
Testing shall be carried out from manhole to manhole. All pipes shall be
subjected to a test pressure of at least 3.0 meters head of water at the
highest point of the section under test. The pipes shall be plugged preferably
with standard drain plugs (with rubber rings) on both ends. The upper end
shall, however, be connected to a pipe for filling with water and getting the
required head.
The contractor shall give a smoke test to the drains and sewers at his
own expense and charges, if directed by the Construction
Manager/Consultants.
Gully traps :
4.6.1
Gully traps shall be of the same quality as described for stoneware
pipes
under para Salt Glazed Stoneware Pipes.
4.6.2 Gully traps shall be fixed in cement concrete 1:4:8 mix and a masonry
chamber 300 x 300 mm. The CI sealed cover and frame shall weigh not less
than 7.3 kg. Where necessary, sealed cover shall be replaced with
CI grating of the same size.
5.0 Reinforced
Cement Concrete Pipes :
All underground storm water
drainage pipe shall be centrifugally spun S& S RCC Pipe of specified class.
Pipes shall be true and straight with uniform bore, through out cracked,
wrapped pipes shall not be used on
the work. The manufacturer and
the Contractor shall test all pipes shall produce, when directed a certificate
to that effect from the manufacturer.
Laying of R.C.C. Pipes:
Loading, transporting and unloading of concrete pipes shall be done
with care. Handling shall be such as to avoid impact. Gradual unloading by
inclined planes or by chain block is recommended. All pipe sections and connections
shall be inspected carefully before being laid. Broken or defective pipes or
connections shall not be used. Pipes
shall be lowered into the trenches carefully. Mechanical appliances may be
used. Pipes shall be laid true to line and grade as specified. Laying of pipe
shall proceed upgrade of a slope.
If the pipes have spigot and socket joints, the socket end shall
face upstream, in the case of pipe with joints to be made with loose collars,
the collars shall be slipped on before the next pipe is laid. Adequate and
proper expansion joints shall be provided where directed.
In cases where the natural foundation is
inadequate, the pipes shall be laid either in concrete cradle supported on
proper foundation or on any other suitable designed structure as specified. If
a concrete cradle bedding is used, the depth of concrete below the bottom of
the pipe shall extend up the sides of the pipe at least to distance of 1/4th of
the outside diameter of pipe. The pipe shall be laid in this concrete bedding
before the concrete has set.
When the pipe is laid in a trench in rock
hard clay, shale or other hard material, the space below the pipe shall be
excavated and replaced with an equalizing bed of concrete, sand or compact
earth. In no place shall pipe be laid directly on such hard material.
When the pipes are laid completely above
the ground, the foundations shall be made even and sufficiently compacted to
support the pipe line without any material settlement. Alternatively the pipe
line shall be supported on p.c.c. saddle blocks. Similar arrangement shall be
made to retain the pipe line in the proper alignment, such as by shaping the
top of the supports to fit the lower part of the pipe. The distance between the
supports shall in no case exceed the length of the pipe. The pipe shall be
supported as far as possible close to the joints. In no case shall the joints
come in centre of the span. Care shall be taken to see that superimposed loads
greater than the total load equivalent to the weight of the pipe when running
full shall not be permitted.
5.3 Jointing of Pipes:
Joints are generally of rigid type. Where specified flexible type
joints may also be provided.
5.4 Spigot and Socket Joint (rigid):
The spigot of each pipe shall be slipped home well into the socket
of the pipe previously laid and adjusted in the correct position. The opening
of the joint shall be filled with stiff mixture of cement mortar in the proportion
of 1:2 (1 cement :2 fine sand) which shall be rammed with caulking tool.
After a day's work any extraneous material shall be removed from the
inside of the pipe and the newly made joint shall be cured.
5.5 Collar Joint
(rigid):
The two adjoining pipes shall be butted against each other and
adjusted in corrected position. The collar shall then be slipped over the
joint, covering equally both the pipes. The annular space shall be filled with
stiff mixture of cement mortar 1:2 (1 cement
:2 fine sand) which shall be rammed with caulking tool.
After a day's work any extraneous material shall be removed from the
inside of the pipe and the newly made joint shall be cured.
5.6 The Testing of
Joints, Refilling of Trenches:
The testing of joints, refilling of trenches for
concrete pipes shall be similar to Specification for stone ware pipes.
6.0 Cement
Concrete for Pipe Support :
a)
Wherever specified or shown on the drawings, all
pipes shall be supported on a bed, all around or in haunches. The thickness and
mix of the concrete shall be as given in the Schedule of Quantities. Width of
the bedding shall be under para Width of Trenches.
b)
Unless otherwise directed by the
Architect/Consultants cement concrete for bed, all around or in haunches shall
be laid as follows:
|
|
Upto 1.5 m Depth |
Upto 3 m Depth |
Beyond 3 m Depth |
|
Stoneware Pipes
in open
ground (no sub soil water) |
All round (1:5:10) |
In haunches (1:5:10) |
In haunches (1:5:10) |
|
RCC or SW in sub soil water |
All round (1:5:10) |
In haunches (1:5:10) |
In haunches (1:5:10) |
|
CI Pipes (in all conditions) |
All round (1:3:6) |
In haunches (1:3:6) |
In haunches (1:3:6) |
|
RCC Pipes or CI pipes under building |
All round (1:3:6) |
In haunches (1:3:6) |
In haunches (1:3:6) |
(1=Cement,
3/5=Coarase sand, 6/10 =Stone aggregate 40 mm nominal size)
c)
RCC pipes or CI pipes shall be supported on brick
masonry or precast RCC or in situ cradles as shown on the drawings or as
directed by the Architect/Consultants.
d)
Pipes in loose soil or above ground shall be supported
on brick or stone masonry pillars as
shown on the drawings or as directed by the Architect/Consultants.
7.0 Manholes and Chambers :
7.1 All
manholes, chambers and other such works as specified shall be
constructed in brick masonry in cement mortar 1:5 (1 cement: 5
coarse
sand) or as specified in the Schedule of Quantities.
7.2 All
manholes and chambers, etc shall be supported on base of cement
concrete of such thickness and mix as given in the Schedule of ]
Quantities or shown on the drawings.
7.3 Where
not specified, manholes shall be constructed as follows:
(All
dimensions are clear internal dimensions in mm)
|
Size of Manholes Type of Manhole |
900x800Rect. |
1200x900 Rect. |
910
dia Circular |
1520
dia Circular |
|
Maximum
Depth |
1000 |
2400 |
2500 |
5000 |
|
Average
thickness of RCC slab |
150 |
150 |
|
|
|
Reinforcement |
As
directed by Architect/Consultants |
|||
|
Size
of Cover and Frame |
600x450 |
560dia |
560dia |
560dia |
|
Weight
of CI/SFRC Cover and Frame |
38 kg light duty |
208 kg heavy duty |
208 kg
heavy duty |
208 kg
heavy duty |
All
manholes shall be provided with cement concrete benching in 1:2:4
nominal mix (1 cement: 2 coarse
sand: 4 stone aggregate 20mm nominal size). The benching shall have slope of
1:10 towards the channel. The depth of the channel shall be full diameter of
the pipe. Benching shall be
finished with a floating coat of neat cement.
All
manholes shall be plastered with 12/15mm thick cement mortar 1:3 (1 cement: 3
coarse sand) and finished with a floating coat of neat cement inside. Manhole
shall be plastered outside as above but with rough plaster with waterproofing
compound.
All
manholes with depths greater than 1m shall be provided with 20 mm square or 25
mm round CI foot rests set in cement concrete blocks 250x100 mm in 1:2:4 mix (1
cement: 2 coarse sand: 4 stone aggregate 20 mm nominal size), at 300 mm centre
to centre vertically and staggered. Foot rests shall be coated with coal tar
before embedding.
All
manholes shall be provided with cast iron covers and frames and embedded in
reinforced cement concrete slab. Weight of cover, frame and thickness of slab
shall be as specified in the Schedule of Quantities or given above.
Testing:
All testing shall be done in accordance with
IS:1172 and IS:5329 except as may be modified herein under.
All lengths of the
sewer/drain/pipelines shall be fully tested for water tightness by means of
water pressure. Testing shall be carried out from manhole to manhole. All pipes
shall be subjected to a test pressure of at least 2.5m head of water. The test
pressure shall, however, not exceed 6m head at any point. The pipes shall be
plugged preferably with upper end shall, however, be connected to a pipe for
filling with water and getting the required head. The sewer/drain/pipeline
shall be filled with water, left to stand for 2 hours, and topped up. The
leakage over 30 minutes shall then be measure and the loss in water shall not
exceed 2 litres/cm of diameter/km of pipeline measured during the last 10
minutes of the period of test.
Sewer lines shall be tested for straightness by:
A) Inserting
a smooth ball 12mm less than the internal diameter of the pipe. In the absence
of obstructions such as yarn or mortar projecting at the joints the ball should
roll down the invert of the pipe and emerge at the lower end,
B) Means of
a mirror at one end and a lamp at the other end. If the pipeline is straight
the full circle of light shall be seen otherwise obstruction or deviation shall
be apparent.
8.4 A
test register shall be maintained which shall be signed and dated by the
Contractor and the Architect/Consultants.
The pipeline shall be covered only
after the testing is successfully completed.
Measurement
and Rates :
Stoneware/RCC/CI
pipes shall be measured for the finished
length of the pipeline per linear
metre.
Lengths between manholes shall be recorded from
inside face of one manhole to inside face of other manhole.
Length between gully trap and manhole shall be
recorded between socket of pipe near gully trap and inside face manhole. Rate
shall include all items given in the Schedule of Quantities and specifications.
9.2 Gully
Traps :
Gully traps shall be measured by the number and rate shall include
all excavation, backfilling, foundation, concrete
brick masonry, cement plaster inside
and outside, CI grating and sealed cover and frame etc complete.
9.3 Manholes
:
a) All manholes shall be measure by
numbers and shall include all items
specified above
and necessary excavation in all types of soils,
refilling, compaction and disposal of surplus earth.
b) Manholes
with depths greater than that specified under the main items shall be paid for
under “extra depth” and shall include all items as given for manholes.
Measurement shall be done to the nearest centimetre. Depth of the manholes
shall be measured from top of the manhole cover to bottom of channel.
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