Water Distribution and Controls

Bahrain Bay Infrastructure
Technical Specifications
Volume 3
Water Distribution & Collection
Networks
JOB NUMBER: RI4326
2
1
0
Revision
Tender Issue
100% CD 2nd Stage Tender Issue
85% Submission For Review
Purpose Description
DOCUMENT REF: RI4326-D905-R3-0021
SA
SA
SA
Originated
ML
RP
DS
Checked
ML
HS
HS
Authorised
18/10/07
08/10/07
19/12/06
Date
BAHRAIN BAY
Technical Specifications - Volume 3
Water Distribution and Collection Networks
Contents
Section
Page
GENERAL REQUIREMENTS
1.1
SCOPE OF WORK
1.1.1
1.1.2
1.1.3
1.1.4
Irrigation
Potable Water and Fire Fighting
Foul Water
Storm
5
5
5
6
1.2
1.3
LAYOUT OF WORK
1.4
CLEAN-UP
1.5
WARRANTY
1.6
TRENCHES AND OTHER EXCAVATION
SUBMITTALS
2.1
MATERIALS, PRODUCT DATA AND EQUIPMENT SCHEDULE
2.2
NO OBJECTION CERTIFICATES
2.3
SHOP DRAWINGS AND VERIFICATION OF DIMENSIONS
2.4
MANUFACTURERS CERTIFICATIONS
2.4.1
2.4.2
Pipes and Fittings

Valves and Special Fittings
9
9
2.5
RECOMMENDATION OF THE MANUFACTURERS
2.6
SPARE PARTS
10
2.7
INSTALLATIONS AND TESTING
10
2.8
MANUFACTURER'S LITERATURE
10
2.9
AS-BUILT DRAWINGS
10
PRODUCT STORAGE AND HANDLING
12
3.1
DEFINITION
12
3.2
TRANSPORTATION AND HANDLING
12
3.3
STORAGE AND HANDLING
12
PIPE WORKS GENERAL REQUIREMENTS
14
4.1
14
4.1.1
4.1.2
4.1.3
Standards Specifications
Scope of Work
Standards
14
14
14
4.2
MATERIALS TO BE FURNISHED BY THE CONTRACTOR
15
4.3
EXECUTION
15
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
Pipe Materials
Pipe Installation
Jointing
Excavation and Backfilling
Underground Warning Tape
15
16
16
17
17
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4.4
POTABLE & IRRIGATION PIPES AND FITTINGS
17
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
High Density Polyethylene Pipe

Jointing
Sampling and Testing
Basis of Acceptance / Rejection
Ductile Iron Pipe And Fittings
Thrust Restraints
17
18
19
20
20
20
4.5
PAINTING
21
4.6
PIPELINE PRESSURE TESTING
22
4.7
CLEANING
22
4.8
DISINFECTION
22
FOUL & STORM DRAINAGE PIPES AND FITTINGS
23
5.1
GENERAL
23
5.1.1
References
23
5.2
PIPE MARKING
23
5.3
HANDLING AND STORAGE
23
5.4
QUALITY ASSURANCE
24
5.5
UNIPLASTICISED POLYVINYL CHLORIDE (uPVC) PIPE AND FITTINGS
24
5.6
GLASS REINFORCED PIPE (GRP) & FITTINGS
26
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.6.6
Testing
Design Parameters to be Considered by the Contractor
Additional requirements: GRP Pipe Data to be Submitted.
Handling and Installation Specification
Tests for GRP Pipes
Required Pipe Data
27
27
28
29
29
33
5.7
DUCTILE IRON PIPE AND FITTINGS
33
PIPE LAYING
34
6.1
GENERAL
34
6.2
PIPE BEDDING
35
6.3
CONCRETE PROTECTION TO PIPES
35
6.4
COMPLETETION OF PIPE SURROUND
36
6.5
BACKFILLING
36
6.6
GULLIES AND DRAINAGE CHANNELS
36
6.6.1
6.6.2
6.6.3
Gullies
Pre-formed Gullies
Manhole
36
37
37
6.7
CONNECTION TO GOVERNMENT MAIN
38
6.7.1
General Requirements
38
6.8
THRUST BLOCKS
39
6.9
VALVES
39
6.9.1
6.9.2
6.9.3
6.9.4
6.9.5
General
Check Valves
Gate Valves
Air Valves
Penstocks
39
40
41
41
42
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6.9.6
Stainless Steel Penstocks
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1.1
SCOPE OF WORK
The work consists of the provision of new services and comprises the installation, testing and
commissioning of the following services networks as summarised below, and as per this
Specification and Contract Drawings.
1.1.1
Irrigation
The system comprises of an irrigation water supply network to meet the irrigation
requirements of the Bahrain Bay for a 24-hour period of irrigation demand. The irrigation
network will be pumped from an irrigation reservoir (by others) located adjacent to the
Sewage Treatment Plant offsite.
The reticulated irrigation supply network covers the Bahrain Bay site and is fed by a single
connection across the North Manama Causeway (NMC) as per the Contract Drawings.
The Scope of Work includes the primary irrigation network, service connections, NMC
crossing terminating adjacent to the offsite STP at the interface point identified on the
Drawings.
The work consists of pipelines with diameters ranging from 150 mm to 300 mm.
1.1.2
Potable Water and Fire Fighting

The potable water supply requirements for the Bahrain Bay development will be supplied by
MEW to the two water reserviors located within the development. From the water reservoirs,
water will be distributed by pressurised system boosted through booster pumps to serve the
development. The fire hydrants are installed along the network with a spacing of 150m
intervals to serve the development with a pressure of 500 GPM in the event of fire. The fire
pumps will be sized to supply the fire demand of 500 GPM through two fire hydrants in the
event of fire with a pressure of 4 bars. The potable water network will have a minimum
network pressure of 1.5 bar and a maximum pressure of 4.5 bar in the network.
The work package comprises of the installation of the primary networks contained within the
development downstream of water reserviors and includes 150mm to 300mm diameter
pipelines the installation of valves, service connections and appurtenances and installation of
the booster pumps and fire fighting pumps.
1.1.3
Foul Water
The proposed foul water system for the Bahrain Bay development is generally a gravity
sewerage system. The infrastructure works shall comprise the construction of the gravity
network sewers with future stub ends located at the parcel boundaries of each development
package. The sewerage network is designed to keep the network above the ground water
table to avoid infiltration into the network.
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Both North and South Island will have independent foul gravity sewers and Foul Pumping
Stations each from where the foul sewer will be pumped through force mains to the Sewerage
Treatment Plant (by others) located offsite.
1.1.4
Storm
The Proposed Storm Water System for the Bahrain Bay development is a gravity drainage
system. The infrastructure works shall comprise of the construction of gravity network drains,
future stub ends located at parcel boundaries, road gullies, gully connections to the main
network and oil interceptors. The Storm Water Drainage outfalls through the Quay walls have
already been installed under the Marine Construction Package. These outfalls have been left
with a pipe protruding out of Quay Walls stone backing for the Infrastructure Contractor to
connect to.
The Storm Drainage Network is designed to keep the network above the groundwater table to
allow the system to be a gravity drainage system. Each of the drainage runs are independent
of the others and will transport the storm water to an oil interceptor before it is released into
the sea.
1.2
Services shall be installed in a sequenced and logical manner to minimise the requirement to
protect any previously installed services.
The Contractor shall include for all materials, labour, plant and tools.
Where new cable/ducts/pipes are to be laid along side, over or under the Contractors
previously installed services, the Contractor shall take care to interfere as little as possible
with the existing services and connections thereto and any damage shall be repaired by the
Contractor to the satisfaction of the Engineer. Any previously installed services shall be
protected before commencing earth works in their vicinity.
All concrete works shall conform to the requirements of the Technical Specifications Volume
13 Concrete.
The Contractor shall be responsible for public safety during execution of work. He will take all
steps, including where necessary the provision of ropes, picket fence, etc. on each side of the
trenches and excavations with warning lights and night watchman, etc. to ensure the safety of
the public. The Contractor will be held responsible for any damage to property or injury to
persons due to his negligence. Any instruction from the Engineer concerning the safety
aspects of the work must be carried out immediately, but the Contractor shall remain
responsible for the adequacy of the safety measures.
1.3
LAYOUT OF WORK
The Contractor shall stake out the water systems in accordance with the design drawings.
Staking shall be erected in such a manner as to ensure permanency of the staked locations
until such time as the respective system is installed. Stakes shall be placed to show location
of valves, pipelines and control head. Stakes shall be flagged with bright flagging for ease of
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location. All staking by the Contractor shall be subject to agreement of the Engineer. Any
stakes disturbed by other works shall be reinstated by the Contractor as early as practicable
in the circumstances.
1.4
CLEAN-UP
During the course of construction, the Contractor shall remove waste material from the site
continually as is necessary to keep the site in an orderly manner. Waste material shall be
removed from the work site and not to be used as back-fill material. Upon completion of the
Contract, the Contractor shall remove all waste equipment and parts and leave the site in a
neat and orderly condition.
1.5
WARRANTY
All work included under this Contract shall be warranted by the Contractor against all defects
and malfunction of materials and workmanship for a period of one year from the date of
completion of works. Should problems arise with the system during the warranty period, all
necessary repairs and/or replacements shall be made by the Contractor in an expedient
manner at no additional cost to the Employer.
1.6
TRENCHES AND OTHER EXCAVATION

All trenches and other excavation shall be maintained in a dry condition and the Contractor
shall arrange a suitable dewatering system for any dewatering involved, in agreement with the
Engineer, to keep the working place clean and dry. The Contractor shall be deemed to have
included in his rates for all costs associated with this work.
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SUBMITTALS
The Contractor shall order materials to suit the construction programme and shall plan
his necessary submittals to the Engineer in accordance with the Technical Specifications
Volume 1 General in a timely manner to suit the ordering, delivery and construction timing
requirements. The Contractor shall submit as a minimum the following documents for review
by the Engineer:
2.1
MATERIALS, PRODUCT DATA AND EQUIPMENT SCHEDULE

All specifications, diagrams, samples, drawings and such other data shall be provided by the
Contractor, in a format to be agreed with the Engineer, which may be required to demonstrate
compliance with the specification.
This shall include but not limited to the following
information:
-
Originals of catalogues and engineering data sheets for manufactured items; each item
and option to be provided shall be clearly marked and each item not to be provided
shall be deleted.
Literature to show that products provided meet the requirements for material,
construction, operation, and testing.
Information on the following items as a minimum: pipes; pipe jointing systems, manhole
covers and frames and gully covers, gratings and frames.
Manufacturer s installation instructions for all items.
Certified reports for all tests and inspections designated herein, signed and sealed,
showing full compliance with referenced standards.
2.2
Maintenance requirements and procedures.
Period of guarantee for products.
NO OBJECTION CERTIFICATES
Prior to start of any work on government property the Contractor has to approach all relevant
Service Authorities in Bahrain to get their no objection for the work included in this contract
and a record drawings for their existing services. Copy of these drawings and no objection
certificate should be submitted to the Engineer before starting the actual work at site. In
addition, for work on Bahrain Bay development land the Contractor shall make all necessary
submissions to the Ministry of Water and Electricity, EDD to obtain their no objection
certificate ensuring that the works covered by this Specification will not invalidate the
adoptability of the High and Low Voltage networks within Bahrain Bay.
All the works executed in Bahrain Bay should be in compliance with the requirements of MEW
and MoWH of Bahrain unless specified otherwise in the Technical Specifications and
Drawings.
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2.3
SHOP DRAWINGS AND VERIFICATION OF DIMENSIONS

The Contractor shall prepare Shop Drawings including but not limited to the following
information
-
Profiles of each pipe system including chainage, ground levels, invert levels, critical
clearances and position of pipework structures.
Material, class, grade, joint type, pressure rating, dimension, location and identification
number of each pipe and pipe fitting to be furnished and installed.
Procedures for building pipes into concrete structures.
Procedures for encasing pipes in concrete.
Class, dimensions, location and identification of each manhole cover and frame to be
furnished and installed.
Procedures for placing and fixing manhole covers and frames.
Class, dimensions, location and identification of each gully cover, grating and frame to
be furnished and installed.
Procedures for placing and fixing gully covers, gratings and frames.
Details for handling and storage of pipes, manhole covers and frames and gully covers,
gratings and frames.
All other miscellaneous details required for complete installation.
The review of Shop Drawings by the Engineer shall not relieve the Contractor of any of his
responsibility under the contract for successful completion of the work.
2.4
MANUFACTURERS CERTIFICATIONS
2.4.1
Pipes and Fittings

Certification by a recognised certification mark scheme such as "The Kitemark" or by an
independent third party testing organization to the satisfaction of Engineer that production has
been carried out under a system for supervision, control and testing, applied during
manufacture, in accordance with Bahrain and British Standards or an equal procedure.
2.4.2
Valves and Special Fittings

Manufacturer's certificate for pressure testing, and coating, including holiday and DFT test
reports for each valve, fitting, spool if applicable.
2.5
RECOMMENDATION OF THE MANUFACTURERS

The
Contractor
shall
submit
manufacturers'
recommendations
for
installation
and
commissioning of each material or piece of equipment prior to commencing work.

Recommendations shall include testing methods, storage requirements and maintenance and
operational data. The Contractor shall have a copy of the manufacturers' instructions
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available on site at all times while work is in progress and shall follow these instructions
unless otherwise authorized to deviate by the Engineer.
2.6
SPARE PARTS
The Contractor shall submit manufacturer's list of spare parts prior to commissioning any
piece of equipment. Recommendations shall include stocking recommendations, exploded
assembly diagrams illustrating location and spare parts to be utilised and all relevant
operational data.
2.7
INSTALLATIONS AND TESTING

The Contractor shall submit his proposed work method statement prior to commencing work.
The statement shall detail proposed sequence of work, hold points, testing frequency and
document control.
2.8
MANUFACTURER'S LITERATURE
At such time as the list of materials has been accepted by the Engineer, the Contractor shall
provide six (6) sets of manufacturer's technical & maintenance literature including M&E
specifications to the Engineer including an electronic copy in PDF format. Data sheets shall
provide sufficient technical information to identify each product and shall include the name
and the address of the nearest supply firm, which should have a local representative in
Bahrain.
2.9
AS-BUILT DRAWINGS
The Contractor shall maintain one set of contract drawings for the sole purpose of recording
accurate changes made as the work progresses ("As-Built" conditions) of the water systems.
All changes previously agreed with the Engineer and all completed work shall be recorded on
these drawings.
The Contractor shall prepare as-built drawings clearly showing all location, depths, slopes,
heights, shapes and dimensions of all works as executed. All valve locations and piping shall
be dimensioned and recorded. The Contractor shall submit as-built drawings for all electrical
installations.
Sizes of all the as-built drawings should be in accordance with MEW-WDD and MoWH-SDD
Standards.
Contractor shall prepare and submit as-built drawings for the pipeline profiles. Pipeline profile
drawings shall be in Horizontal scale of 1:1000 and Vertical scale of 1:100. Pipeline profiles
shall be submitted on separate drawings with clear references to layout drawings marked on
the same.
Chambers Schedule shall be prepared indicating all relevant construction items and giving coordinates for each manhole in compliance with Bahrain grid System.
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The Contractor shall submit as-built drawings for all the electro-mechanical installations. All
details of the installed equipment regarding Manufacturer, and Model No., Type, size, etc.,
shall be provided in the legend of the drawings.
After final acceptance of the As-Built Drawings, the Contractor shall submit the required sets,
as specified in the Technical Specifications Volume 1 General.
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PRODUCT STORAGE AND HANDLING
3.1
DEFINITION
Products mean new material, machinery, components, equipment, fixtures, and systems
forming the Work.
It does not include machinery and equipment used for preparation,
fabrication, conveying and erection of the Works.
Products may also include existing
materials or components required for re-use.

The Contractor shall not use materials and equipment removed from existing premises,
except as specifically permitted by the Engineer or provided in the Technical Specifications.
The Contractor shall provide interchangeable components of the same manufacturer, for
similar components.
3.2
TRANSPORTATION AND HANDLING

All products shall be delivered in the manufacturers' original protective packaging and shall be
inspected at time of delivery. Any products, which are damaged and not in accordance with
specifications, or date stamp expired, shall be immediately removed from the site and
replaced.
The Contractor shall promptly inspect shipments to assure that products comply with
requirements, quantities are correct, and products are undamaged.
Evidence must be submitted to verify that materials have been properly protected during
transport and storage prior to delivery to the site.
All products shall be handled and stored in accordance with printed recommendations of the
manufacturer.
The Contractor shall be responsible for transport of pipes from the manufacturing plant to the
site storage yard for proper stockpiling. Every shipment, upon reaching the storage yard shall
be subjected to one hundred percent (100%) visual inspection. If more than two percent (2%)
of the pipes shipped are found with visible damage, a representative sample equivalent to five
percent (5%) of the lot, selected at random, shall be subjected to hydrostatic test at 1.0 MPa
(150 psi), the pressure maintained for thirty (30) seconds. Any pipe failing this test shall be
immediately removed from site. If twenty percent (20%) or more of the five percent (5%)
samples fail, the whole lot shall be subjected to hydro test. Any pipe failing this test shall be
immediately removed from site.
All pipe and accessories shall be stored on flat, level ground with no rocks or other objects
under the pipe. The maximum recommended stacking height for HDPE pipe shall be in
accordance with the manufacturers recommendations.
3.3
STORAGE AND HANDLING

The Contractor shall store and protect products in accordance with manufacturer's
instructions, with seals and labels intact and legible and store sensitive products in an
appropriate manner whether shaded, weather-tight, climate controlled or the like.
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Fabricated products stored externally shall be placed on pallets or other means of above
ground storage.
The Contractor shall provide off-site storage and protection when the site does not permit
on-site storage or protection.
The Contractor shall cover products subject to deterioration with impervious sheet covering
and provide ventilation to avoid condensation.
The Contractor shall provide equipment and personnel to store products by methods to
prevent soiling, disfigurement, or damage.
The Contractor shall arrange storage of products to permit access for inspection and shall
periodically inspect producte to assure that the products are undamaged and are maintained
under specified conditions.
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PIPE WORKS GENERAL REQUIREMENTS
4.1
4.1.1
Standards Specifications
This section deals with the specification for works to be carried out in connection with Water
Services pipe work.
All pipe material used for constructing the potable water distribution network and irrigation
water distribution network should be of HDPE fit for respective use and from a manufacturer
agreed with the Engineer.
General requirements for the potable water and irrigation water works shall conform to the
Ministry of Electricity and Water (MEW), Water Distribution Directorate and the Ministry of
Works and Housing (MoWH), Sewerage and Drainage Directorate specifications respectively
and the specific requirements of this Technical Specification.
Foul water network pipe material for diameters up to and including 300mm should be of uPVC
capable of handling foul sewer, fit for respective use and from a manufacturer agreed with the
Engineer. Foul water network with pipe diameter above 300mm should be of GRP capable of
handling foul sewer water, fit for respective use and from a manufacturer agreed with the
Engineer.
Storm Water Network pipe material for diameters up to and including 400mm should be uPVC
capable of handling storm water, fit for respective use and from a manufacturer agreed with
the Engineer. Storm water network with pipe diameters above 400mm should be of GRP
capable of handling storm water, fit for respective use and from a manufacturer agreed with
the Engineer.
General requirements for the foul and storm water works shall conform with the MoWH SDD,
Standard Specification for Sewerage and Drainage Civil Engineering Works and the specific
requirements of this Technical Specification.
4.1.2
Scope of Work
The works include for the supply, installation, testing and commissioning of the Water
Services installation, the layouts for which are shown on the Drawings. Future connection for
the secondary and tertiary irrigation system will be undertaken using saddle connections and
shall be the responsibility of the tertiary irrigation system designer. However, the Scope of
Works does include service connections that are detailed in the Drawings.
The Contractor shall include for all labour, materials, tools and tackle, complete with all
trenching and backfill.
The Contractor shall include for the preparation for all necessary working Drawings. The
Contractor shall be responsible for the correct setting out of the installation.
4.1.3
Standards
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All calculations, drawings and submissions shall be in SI (System International) units. Material
items shall be to the latest BS (British Standard) or equivalent comparable internationally
recognised standard of construction and quality.
4.2
MATERIALS TO BE FURNISHED BY THE CONTRACTOR

All materials shall be provided by the Contractor, unless otherwise specified, including but not
limited to pipes, collars, rubber rings, valves, hydrants to the approval of Civil Defence and
fittings.
The materials provided by the Contractor shall include all materials for temporary works,
planking and strutting, excavations, shuttering and formwork, staging and scaffolding,
compliant filling materials, all materials required for repairing the internal coating of valves,
etc., such as primer, coal tar enamel etc., all concrete of each required class including
reinforcing steel and mesh, all surface boxes etc.
All materials supplied locally by the Contractor shall be of the best quality in their class and of
the respective kinds as described in the Contract and in accordance with the Engineer's
instructions and to the satisfaction of the Engineer. They shall be inspected from time to time
at the site during the progress of the work.
Any materials arriving on site found unsuitable shall be rejected. The Contractor shall replace
the rejected material at his own expense.
The Contractor shall, before supplying any local material, prepare and submit, at his expense,
to the Engineer for review samples of materials which he proposes to use. Such samples
shall be retained by the Engineer. The materials represented shall not be used in the works
unless and until the samples have been accepted in writing by the Engineer.
4.3
EXECUTION
4.3.1
Pipe Materials
Table 4.1: Pipe Material Schedule

Service
Foul Sewer
Foul Sewer Pressure Main
Rider Sewer
Storm Water
Irrigation Main
Potable Water
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Pipe Dia (mm)
Location
Material
300 and below

350 and above
100 / 150
350
100 /150 / 350
150
400 and below
450 and above
All
All
Land
Land
Land
Land
Bridge
Land
Land
Land
Land
Bridge
uPVC
GRP
GRP
GRP
DI
uPVC
uPVC
GRP
HDPE
Epoxy lined DI
All
All
Land
Bridge
HDPE
Cement lined DI
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4.3.2
Pipe Installation
Pipe installation shall be in accordance with the general pipe laying requirements of the WDD
and SDD Standard Specifications and the specific requirements as follows:
-
Necessary facilities including slings shall be provided for lowering and properly placing
the pipe section in the trench without damage. The pipe sections shall be laid to the line
and grade shown and they shall be closely jointed to form a smooth flow line.
Immediately before placing each section of pipe in final position for jointing, the bedding
for the pipe shall be checked for firmness and uniformity of surface.
At all times when the work of installing pipe is not in progress, all openings into the pipe
and the ends of the pipe in trenches or structures shall be kept tightly closed to prevent
entrance of animals and foreign materials. The Contractor shall take all necessary
precautions to prevent the pipe from floating due to water entering the trench from any
source, shall assume full responsibility for any damage due to this or any other cause,
and shall at his own expense restore and replace the pipe to its specified condition and
grade if it is displaced. The Contractor shall maintain the inside of the pipe free from
foreign materials and in a clean and sanitary condition until handover.
All piping and fittings shall be installed true to alignment and rigidly supported.
Anchorage shall be provided where required. Any damage to linings shall be repaired
to the satisfaction of the Engineer before the pipe is installed. Each length of pipe shall
be cleaned out before installation. All of manufacturer's recommendations shall be
complied with.
The deflection at joints shall not exceed that recommended by the pipe manufacturer.
Fittings, in addition to those shown on the Drawings, shall be provided, if required, in
areas where conflict exists with the existing facilities.
When pipe cutting is acceptable to the Engineer, the cutting shall be done by abrasive
saw, leaving a smooth cut at right angles to the axis of the pipe. Any damage to the
lining shall be repaired to the satisfaction of the Engineer.
4.3.3
Jointing
Jointing shall conform to WDD and SDD Standard Specifications and the following specific
requirements.
-
Flanged joints shall be made using gaskets, bolts, bolt studs with a nut on each end, or
studs with nuts where the flange is tapped. The number and size of bolts shall conform
to the same ANSI Standard as the flanges.
Bolts in flanged joints or mechanical joints shall be tightened alternately and evenly.
Sleeve type couplings and grooved joints using split ring couplings shall be installed in
accordance with the procedures recommended by their respective manufacturers.
All pipe and appurtenances connected to equipment shall be supported in such a

manner as to prevent any strain being imposed on the equipment.
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BAHRAIN BAY
manufacturers have indicated requirements that piping loads shall not be transmitted to
their equipment, submit a certification stating that such requirements have been
complied with.
4.3.4
Excavation and Backfilling

Excavation and backfilling shall conform to WDD and SDD Standard Specifications unless
specified otherwise in the Technical Specifications.
4.3.5
Underground Warning Tape

The Contractor shall install specified warning tapes during backfilling work over buried pipes,
cables, conduits and ducts, as required. Warning tapes shall be coloured and inscribed for
identification according to the requirements below.
Table 4.2: Underground Warning Tape Requirements

Service
Foul Sewer
Foul Sewer Pressure Main
Irrigation Main
Storm Drain
Potable Water Main
Colour
Red
Red
Orange
Grey
Blue
Caution
Caution: Sewage Pipe Below
Caution: Sewage Pressure Main Below
Caution: Irrigation Pipe Below. Not for Drinking.
Caution: Storm Drain Below
Caution: Water Main Below. (Potable water mains
shall be protected in accordance with the requirements
of the MEW, Water Distribution Directorate,
Specifications of Items for Water Supply
All warning tapes shall be submitted to the Engineer for acceptance prior to delivery to site.
Warning tape shall be high quality, acid and alkali-resistant polyethylene film 300 mm wide,
and with a minimum thickness of 0.10mm. The tape shall be laid in a continuous manner
above each service at depth of 0.3m below ground level, and shall be continuously and
indelibly marked in English and Arabic with the appropriate wording.
Tape shall be printed with 50 mm high black lettering or white lettering where the tape is
black. The complete wordings shall be repeated every 2m along the tape. The colours shall
be vivid, glossy and permanent with a life expectancy of 40 years.
Warning tapes shall be placed with the inscriptions facing upwards. The level of the tape
relating to the top of service shall be in accordance with the requirements of the relevant
services standard detail Drawings.
Warning tapes over non-metallic services shall be backed with Aluminium foil to facilitate
detection.
4.4
POTABLE & IRRIGATION PIPES AND FITTINGS
4.4.1
High Density Polyethylene Pipe
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-
Polyethylene pipes shall be High Density Polyethylene (HDPE) manufactured and

tested in accordance with ISO 4427 (Polyethylene Pipes and Fittings for Water Supply
Specification). The polyethylene pipe shall be designed to sustain a maximum working
stress of 50 bar at 20C. The wall thickness shall be based on a nominal pressure
rating (PN) of 10 bar.
Except as otherwise indicated, the current editions of the following Standards apply to
the work in this section;
a.
ASTM D 2447-95
- Standard Specification for Polyethylene (PE) Plastic Pipe,
Schedules 40 and 80, based on Outside Diameter

b.
ASTM F 714-95
- Standard Specification for Polyethylene (PE) Plastic Pipe,
(SDR-PR) based on Outside Diameter

-
Polyethylene pipes with outside diameter less than or equal to 12 (406 mm) shall be
manufactured under ASTM D 2447-95 -Standard Specification for Polyethylene (PE)
Plastic Pipe, Schedules 40 and 80, based on Outside Diameter while polyethylene
pipes with outside diameter greater than 12 (406 mm) shall be manufactured under
ASTM F 714-95 -Standard Specification for Polyethylene (PE) Plastic Pipe, (SDR-PR)
based on Outside Diameter.
All compound used shall be virgin plastic. Clean work material from the manufacturers
own pipe production maybe used so long as the original was virgin material and of the
same type, class and grade as required above.
Pipes shall be manufactured from polyethylene containing only those antioxidants, UV

stabilizers and pigments necessary for the manufacture of pipes and conforming to this
Specification and for its end use, including weldability, when it is possible.
When used under conditions for which they are designed, pipe materials shall not
constitute toxic hazard, shall not support microbial growth and shall not give rise to
unpleasant taste or odour, cloudiness and discoloration of the water.
The pipe shall be homogeneous throughout and essentially uniform in colour, opacity,
density, and other properties. The inside and outside surfaces shall be semimatte or
glossy in appearance (depending on the type of plastic) and free of chalking, sticky, or
tacky material. The surfaces shall be free of excessive bloom, that is, slight bloom is
acceptable. The pipe walls shall be free of cracks, holes, blisters, voids, foreign
inclusion, or other defects that are visible to the naked eye and that may affect the wall
integrity.
4.4.2
Jointing
The jointing system for HDPE pipes and fittings shall be in accordance with the butt-fusion
method and the pipe manufacturers recommendations subject to acceptance by the
Engineer. When the pipes supplied under these Specifications are installed and joined by this
method, the work shall be carried out only by well-qualified personnel who adhere strictly to
prescribed working conditions, using tools and procedures recommended by the manufacturer
and accepted by the Engineer.
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-
Equipment - The equipment needed shall be as described in ASTM D-2657.
General Procedure - The following procedure shall be followed when making a buttfusion joint unless agreed otherwise with the Engineer:
a.
Wipe each pipe-end clean, inside and out to remove dirt, water, grease, and
other foreign material.
b.
Square off the end of each pipe section to be used using a facing tool. Remove
cuttings and burrs from pipe ends.
c.
Check line-up of pipe-ends in fusion machine to see that pipe ends meet
squarely and completely over the entire surface to be fused. Two clamps should
be used on each end of pipe to be fused for sizes 100 mm and above.
d.
Insert the heater plate between the aligned pipe ends. Bring and hold the pipe
ends in contact with the heater plate. Maintain contact and allow pipe to heat and
soften until a bead of molten plastic rolls back from the ends. This bead will be
about 1.5 mm to 5.0 mm back from the end of the pipe depending on size. Soften
approximately 1.5 mm on all sizes up to 75 mm; on 75 mm to 150 mm heat to 3
mm and for the above 150 mm heat to 5 mm. Softening can be judged by the
appearance of the pipe end as the material softens.
e.
Both surfaces of the heater plate shall be clean and the temperature maintained
at 2460C-2600C (4750F to 5000F).
f.
Carefully move the pipe ends away from the heater plate and remove the plate.
If the softened material sticks to the heater plate, discontinue the joint. Clean
heater plate, re-square pipe ends and start over.
g.
Bring the heated pipe ends together with the specified pressure to form a uniform
double bead about 3 mm to 5 mm wide around the entire circumference of the
pipe.
h.
Allow the joint to cool and solidify while maintaining the pressure for the specified
time. Inspect the joint for a uniform non-porous appearance. If the joint appears
faulty, cut the joint out and repeat the procedure.
4.4.3
Sampling and Testing

At least one piece or set (depending on the quantities specified by the test method) of
sample/s per production batch (one production run or one production shift, whichever is
shorter) shall be taken at random for testing in accordance with the methods and procedures
specified in the appropriate Standard.
-
ASTM D 2447-95 Standard Specification for Polyethylene (PE) Plastic Pipe,

Schedules 40 and 80, based on Outside Diameter
ASTM F 714-95 Standard Specification for Polyethylene (PE) Plastic Pipe, (SDR-PR)
based on Outside Diameter
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The pipes shall be tested in accordance with the methods prescribed in this standard. The
frequency of sampling and testing of pipes shall also follow the procedures stated in this
standard.
4.4.4
Basis of Acceptance / Rejection

All samples must pass the required tests for the whole lot to be accepted. Failure of one
sample would require a confirmation test on another set of two (2) samples collected at
random from the same lot. The said lot shall be accepted if all confirmation samples pass the
tests.
4.4.5
Ductile Iron Pipe And Fittings

The Contractor shall furnish all labour, materials, equipment and incidentals required, install,
and test ductile iron pipe and fittings for the pipe networks as shown on the Drawings and as
specified herein.
All ductile-iron pipe and fittings to be installed under this project shall be inspected and tested
at the foundry as required by the standard Specifications to which the material is
manufactured and in accordance with MEW WDD materials requirements. The Contractor
shall furnish in duplicate to the Engineer sealed certificates of such tests and their results prior
to the shipment of the pipe.
All ductile-iron pipes and fittings shall be from a single manufacturer and shall comply with
WDD and SDD Standard Specifications.
Ductile iron pipe and fittings shall conform to BSEN 545 current at time of Tender in
accordance with the requirements of the WDD and SDD Standard Specifications.
4.4.6
Thrust Restraints
-
General
a.
Ductile Iron pipe and fittings requiring thrust restraint shall be furnished with
push-on restrained joints or mechanical joint restraints as required.
Push-On Restrained Joints

b.
Restrained joints shall be "Flex-Ring" or "Lok-Ring" restrained joints as

manufactured by American Ductile Iron Pipe or equal to the satisfaction of the
Engineer. Field-adaptable restraint shall be provided through the use of "FastGrip" or "Field Flex-Ring" as manufactured by American Ductile Iron Pipe, or
bolt-less, push-on restrained devices to the satisfaction of the Engineer. When
restrained joints require factory welding, the Manufacturer shall qualify all
welding procedures and welders used to produce the product as per the
requirements of a documented quality assurance system based on ANSI/AWS
D11.2. Unless otherwise specified, gasket material shall be standard styrene
butadiene copolymer (SBR). Restrained joints and restrained joint pipe shall be
rated for the minimum pressure shown in Table 306.3 or the specified pressure
rating of the pipe, whichever is less. The Manufacturer shall furnish test results
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showing that restrained joints in the sizes specified have been successfully
tested to at least twice the specified pressure rating of the joint without leakage
or failure. Tests shall be performed on pipe with nominal metal thickness less
than or equal to that specified for the project. Torque-activated restrained joint
devices that rely on threaded bolts or set-screws for joint restraint shall not be
used.
Table 4.3: Restrained Joints Pressure Ratings

RESTRAINED JOINT PRESSURE RATINGS, (psi) & ALLOWABLE JOINT DEFLECTIONS
(Limited to the pressure rating of the pipe)
JOINT SIZE
FAST-GRIP
FIELD FLEX-RING
FLEX-RING
100mm
350 / 5o
350 / 5o
o
150mm
350 / 5
350 / 5o
o
200mm
350 / 5
350 / 5o
o
250mm
350 / 5
350 / 5o
o
300mm
350 / 5
350 / 5o
o
o
350mm
250 / 4
350 / 4
350 / 4o
o
o
400mm
250 / 3
350 / 3.75
350 / 3.75o
o
o
450mm
250 / 3
350 / 3.75
350 / 3.75o
o
500mm
250 / 3o
350 / 3. 5
350 / 3. 5o
600mm
250 / 3o
350 / 3o
350 / 3o
o
o
900mm
150 / 2. 5
250 / 2. 5
250 / 2. 5o
Mechanical Joint Restraints

c.
Restrained joints shall be mechanical joint restraining glands, incorporating a

number of individually actuated wedges. The assembled joint shall maintain its
flexibility after burial and shall maintain its integrity by a controlled and limited
expansion of each joint during the wedging action. Restraining glands shall be
manufactured of ductile iron conforming to the requirements of ASTM A 536,
Grade 65-45-12. Wedging mechanisms shall be manufactured of ductile iron
heat treated to a hardness of 370 BHN minimum and shall be contoured fit each
pipe size exactly. Dimensions of the gland shall be such that it can be used with
the standardized mechanical joint bell and tee head bolts conforming to the
requirements of ANSI/AWWA C111/A21.11 and ANSI/AWWA C153/A21.53 of
latest revision. Twist off nuts shall be incorporated in the design of the wedge
activation screws to insure proper torque during installation.
d.
The mechanical joint restraining device shall have a working pressure rating of
200 psi minimum with a safety factor of at least 1.5:1 against separation when
tested in the dead-end situation.
4.5
PAINTING
Dry film thickness (DFT) of all painted valves and spool pieces shall be measured on delivery
to site. DFT shall be the average of no less than three measurements, with no one
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measurement less than 75% of nominal average DFT. Holiday tests shall be carried out on
internal and external surfaces on delivery, and also on external surfaces prior to back filling.
4.6
PIPELINE PRESSURE TESTING

Hydrostatic field tests shall be conducted on the pipelines to a minimum pressure of 1.5
working pressure and in accordance with the WDD and SDD Standard Specifications.
4.7
CLEANING
Clean the entire pipe by flushing with water or other means to remove all dirt, stones, pieces
of wood, or other material which may have entered during the construction period. All debris
shall be removed from the pipeline. The lowest segment outlet shall be flushed last to assure
debris removal.
4.8
DISINFECTION
Once completing distribution network and after performing all other necessary system
operating tests to obtain acceptance from the Engineer for taking over of the completed
system the Contractor should proceed to perform disinfection on the system through WDD
approved method and the system should be disinfected in the presence of the Employers
Representative and the Engineer for obtaining a taking over certificate.
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FOUL &
FITTINGS
5.1
GENERAL
STORM
DRAINAGE
PIPES
AND
This Part specifies the requirement for pipework, gullies, manholes, catch pits, and other
items related to drainage. Related Sections and Parts are as follows:
5.1.1
References
The following standards are referred to in this Part:
-
BS 497 Manhole covers, road gully grating and frames for drainage purposes
BS 743 Materials for damp-proof courses
BS 1142 Fibre building boards
BS 1247 Manhole steps
BS 2494 Elastomeric seals for joints in pipework and pipelines
BS 4660 unplasticized polyvinyl chloride (PVC-U) pipes and plastic fittings of nominal
sizes 110 and 160 for below ground gravity drainage and sewerage
BS 6076 Tubular polythene film for use as protective sleeving for buried iron pipes and
fittings
BS 548 1 unplasticized PVC pipe and fittings for gravity sewers
BS 59 11 Precast concrete pipes, fittings and ancillary pro ducts
BSEN 124 Gully tops and manhole tops for vehicular and pedestrian areas
BS 2494 Elastomeric seals for joints in pipework and pipelines
BS 5480 Glass reinforced plastic (GRP) pipes and fittings for use for water supply or
sewerage
5.2
PIPE MARKING
Each pipe and pipe fitting shall be marked with the following:
5.3
Serial number
Class of pipe
Nominal diameter
Name or trademark for manufacturer
Date of manufacture.
HANDLING AND STORAGE

Each item to be provided under this Part shall be stored and handled in accordance with the
recommendations of the manufacturer of the item.
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Products susceptible to ultra violet degradation shall be stored under cover and out of direct
sunlight.
Pipes and fittings shall be subject to visual inspections after off-loading at the site and before
installation.
5.4
QUALITY ASSURANCE
Pipes, pipe fittings, manhole covers and frames and gully covers, gratings and frames shall
be supplied by manufacturers acceptable to the Engineer as designated in the Technical
Specifications. Production facilities shall be quality assessed in accordance with ISO 9000.
5.5
UNIPLASTICISED POLYVINYL CHLORIDE (uPVC) PIPE AND FITTINGS

All uPVC pipes and fittings shall be from a manufacturer acceptable to the Engineer.
Recycled material shall not be used for manufacture uPVC products.
Seal rings for joints shall be EPDM rubber, resistant to sewerage, chemical agents etc.
Manufacturer shall provide corporate guarantee for performance of 60 years.
60 years
guarantee means that if the pipe is exposed and retested after 60 years of service then it
should retain at least 80% of its original properties.
With each consignment the supplier shall along with his delivery note, routine QC test reports
that shall also include the batch numbers that comprises the consignment, date of production
and numbers from each batch.
The traceability system of the supplies shall be such that it should be able to trace any failure
at least up to the raw material sources.
Any personnel from the Employer, his representatives or the Engineer wishing to visit the
supplier's yard, testing arena, storage area, etc. shall immediately be given access. If any
regular/random test, raw materials invoices or QA/AC records are requested to check the
continued compliance, such request shall be responded to immediately.
Pipes and fittings shall generally comply with DIN 8061/8062/8063 series unless particular
deviations and/or references are made. Irrespective of the application at the site all the PushFit-Rubber-gasketed jointed pipes shall be pressure rated into classes 6, 10 or 16 as
specified.
The following Table 5.1 specifies the minimum particular requirements/tests to be carried out
at the given frequency. Where appropriate, ISO 4422 shall be followed with a factor of safety
2.5 for both specification and test method. The standards mentioned (latest at time of Tender)
here are for specific compliance. Nevertheless this in no way replaces the Contractors and
any other organization's testing regime. All the test Certificates shall be retained for at least
10 years for any inspection and auditing.
The percentage of PVC in the pipe shall not be less than 90% when tested by a loss on
ignition test. The K value that is used in designing the network is generally 0.06, as per
Colebrook and White Designing charts and the pipes supplied shall possess this value of
friction co-efficient.
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Pipes shall be completely circular and no-ovality or bending from straightness is permitted.
If any random test fails in any property the batch from which the sample was taken shall be
rejected and immediately removed from the site. In addition three (3) further samples from
batches identified by the Engineer shall be tested and if any one of these three (3) further
samples fails then the supplier(s) of the materials shall no longer be considered acceptable
and all material from the supplier(s) shall be removed from site and the Contractor shall
submit details of alternative supplier(s) all at no cost to the Employer.
Any discrepancy/contradiction among/within Specifications, Standards, Drawings, etc.
immediately shall be brought to the notice of the Engineer for further clarification.
Table 5.1: Restrained Joints Pressure Ratings (uPVC)

Specs.
Test Method
Density
Marking
DIN 8062
DIN 8062
ASTM D792
Visual
Short Term Hydro Test @ 20C

EPDM Gasket Tests
Impact at 0C
Joints Tightness (each size/class)
Water Absorption
Vicat Softening
Heat Reversion
Yield Stress & Elongation
DN 8061
EN 681-1
ISO 3127
ISO 4422
DIN 8061
ISO 2057
DIN 8061
ISO 6259
ISO 1167
EN 681-1
ISO 3127
ISO 4422
DIN 8061
ISO 2507
ISO 2505
ISO 6259
ISO 4422-2
ISO 3473
DIN 8062
ISO 7686
ISO 3473
ISO 3126
Wall thickness
DIN 8062
ISO 3126
Resistance to Acetone
ISO 3472
ISO 3472
Loss on Ignition
MRS-Value > 10 000 hrs test
Appearance
ISO 4422
DIN 8061
ASTM D2584
ISO/TR 9080
DIN 8061
Opacity
H2SO4 Resistance
Outer Diameter
Freq.
Test
Remarks
D Shall be < 1.44 g/cm3

F Contract No. Also, every
2m
A DIN 8062 also
C EPDM only
B TIR<10%
D
--D < 4mg/cm2
D > 79C
A < 5%
B Yield >45MPa and
Elongation >80%
A
--D
--A If ISO 161/1 then tolerance
ISO 3606
A If ISO 4065 then tolerance
ISO 3606
A No
delamination/disintegration
B No more than 10% residue
E First one within 2 years
A
---
Freq. Legend: A-Every Shift; B-Monthly; C-Yearly; D-Once a Contract; E-5 Yearly;
F-Every Pipe
Pipe classes shall be in accordance with following table:

Table 5.2: Restrained Joints Pressure Ratings
Diameter OD
(mm)
160
225
280
315
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< 8m cover between Final

Ground Level and Invert
> 8m cover between Final

Ground Level and Invert
Class 10
Class 10
Class 10
Class 10
Class 16
Class 16
Class 16
Class 16
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5.6
GLASS REINFORCED PIPE (GRP) & FITTINGS

All GRP pipes and fittings shall be from manufactures acceptable to the Engineer. The GRP
pipe and fitting laminate shall consist of an inner chemical resistant layer (liner) and an outer
structural layer.
All pipes shall be manufactured either by centrifugal system or by filament winding process
employing a dual helix angle winding pattern, using pre-stressed continuous glass rovings.
The filament wound pipe shall be made on a straight steel mandrel with only slight taper to
facilitate demoulding of the pipe from the mandrel.
Centrifugally cast GRP pipes shall be acceptable if, in addition to all requirements stipulated
for GRP pipe manufactured by other process are complied, the following requirements are
also met:
-
Flexural modulus of the pipes shall not be taken into account.
The maximum sand content in the structural wall of storm water drainage, foul
sewerage and all pressure pipes shall not exceed the allowed limit. Sand shall not be
permitted in the inner chemical resistant layer.
If the manufacturer prefers not to use a veil tissue of ECR or C glass, then it shall be
replaced it with only a vinyl ester resin.
No pigments or dyes may be incorporated into the laminate and no sand fillers may be
present in the inner chemical resistant layer. Pipes and fittings for pressure mains shall not
incorporate sand in outer structural layer. High purity silica sand may be incorporated into the
structural layer of pipes and fittings for gravity flow application and diameters greater than
400mm though under no circumstances will the sand content exceed 30%. All other gravity
mains shall not incorporate sand in the structural layer.
The inner chemically resistant layer (liner) shall be composed of either a vinyl ester Derakane
411-45 from Dow Chemicals or Repoxy R-802 from Showa High Polymer or exact equivalent
even in raw materials used. This inner layer shall have a minimum thickness of 2mm for pipes
conveying foul or effluent water and 1mm for pipes conveying storm or clean water and the
inner surface shall be reinforced with 'C' glass. The resin content by weight reducing form
approximately 90% at the inner surface to 65% - 75% at the outer surface of the liner.
The outer structural layer shall be composed of isophthallic resin, resistant to mineral acid of
PH lower than 2.0, reinforced with 'ECR' (electro corrosion resistant) glass rovings, for pipes
conveying foul or effluent water or 'E' glass rovings for pipes conveying storm or clean water
as appropriate to give a final product of sufficient strength to meet the tensile and flexural
requirements of the pipe. The exterior surface shall be relatively smooth with not exposed
fibres or projections.
Where the Engineer has accepted use of a manufacturing process which precludes the
possibility of liner pre-gelling, an acid resistant grade 'ECR' glass reinforcement shall be used
for pipes conveying foul or effluent pipes, 'E' glass for pipes conveying storm or clean water.
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The results of the strain-corrosion tests carried out in accordance with ASTM-D3681 whilst
the pipe is exposed to 10% sulphuric acid at a temperature of 50C shall indicate that the pipe
has lifetime of 60 years under operating conditions.
5.6.1
Testing
The following tests shall also be carried out by pipe manufacturers at their works. The results
of these tests shall be made available to the Engineer on request. The Engineer shall also be
allowed to witness some or all those tests.
-
Works hydraulic tests:

a.
Pipes and fittings for gravity application 1 pipe in 30 to be hydraulically tested

to 1.5 bars internal pressure.
b.
Pipes and fittings for pressure application All to be hydraulically tested to a

rated pressure, if specified, or to three times the maximum sustained operating
pressure or to 25 bars internal pressure whichever is the lesser.
c.
The above tests to be in accordance with BS 5480 and a minimum duration of

test to be 5 minutes.
d.
Joints for gravity application 1 joint in every 100 pipe/fitting produced shall be
tested in accordance with ASTM-D3262-81.
e.
Joints for pressure application 1 joint in every 100 pipe/fitting produced shall be
tested in accordance with ASTM-D3517-81
Raw materials - All raw materials shall be tested by sampling for consistency to their
Specification. No change of raw material source shall be permitted for a particular
application.
Wall thickness - Shall be measured for every pipe.
Stiffness - Test shall be carried out to ASTM-D2412 and at a frequency of 1 pipe in 30.
Beam Strength - Tests shall be in accordance with ASTM-D3262 for gravity pipe and
ASTM-D3517 for pressure pipe and at a frequency of 1 pipe in 100 shall apply.
Reinforcement Content - An analysis of glass reinforcement, resin and filler content of a

minimum of 1 pipe in 30 shall be made. The tests shall include analysis of the inner
liner by separation from the structural layers before ignition.
Cure of pipe - A Barcol Hardness test for cure of internal and external surfaces shall be
made on a minimum of 1 pipe in 30. A minimum figure of 85% of the resin supplier's
recommended hardness shall be required.
5.6.2
Design Parameters to be Considered by the Contractor

The following design parameters shall be considered by the Contractor in selecting products:
-
The maximum pressure attained in the pipeline inclusive of surge shall not exceed the
maximum sustained working pressure rating of the pipe.
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-
The surge pressure amplitude (i.e. the difference between the maximum and minimum
surge pressures) shall not exceed one half of the maximum sustained working pressure
of the pipe.
The pipe shall have a minimum stiffness of 10,000 N/m for depth greater than 8m and
5000 N/m for a depth of less than 8m.
The maximum long term diametrical deflection shall not exceed 5%.
Wall strains shall be limited to values declared by the manufacturer on the basis of long
term performance test information. Typically, these shall be a maximum of 0.5% when
calculating wall strains using the formula.
e = Df. (d/D) (t/D)
where,
e = strain
d = diametrical deflection in mm
t = pipe wall thickness in mm
D = pipe diameter in mm and
Df is a factor primarily dependent on the ratio of pipe stiffness to soil stiffness on
the bedding. The values of Df to be adopted shall be as follows:
Pipe Stiffness (N/mm2)
Df
5,000
10,000
30,000
5.6.3
6
5
4
Additional requirements: GRP Pipe Data to be Submitted.

The following details of GRP pipes and fittings shall be submitted to the Engineer.
-
Detailed description of manufacturing process.
Data for each class of each diameter of pipe.
Details of all resins to be used in the manufacture including the name, manufacturer,
type and properties.
Details of all curing agents, flexibilisers and other additives shall
also be given.
-
Details of glass fibre including type, name of manufacture and tex of rovings.
Details of all aggregates used in the manufacture including a sieve analysis and particle
gradation curve for each aggregate.
Details of joints and rubber rings or gaskets including ring or gasket manufacturer's
name, type, and reference number, rubber type and hardness, calculations to show that
the stretch and compression of the ring will be within the range recommended by the
manufacturer. A copy of these recommendations and fully dimensioned drawings of
joints. These drawings shall show the main pipe barrel and the complete joint between
two pipe ends. Dimensions of internal diameter, wall thickness, length of joint and the
extent of all shaping, cut outs etc., should be indicated on the drawing together with the
manufacturing tolerances on these dimension for each class of each diameter of pipe.
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5.6.4
Details of all fittings including fully dimensioned drawings.
Results of all type tests as required by the Specifications
Handling and Installation Specification

The pipe Manufacturer's Specification shall take account of and incorporate the requirements
of the following:
-
All details should be provided relating to the handling and storage of GRP pipes
including:
a.
pipe and rubber ring storage facilities
b.
site transport
c.
lifting methods
Full details with sketches of installation procedures in open trench and such other
methods of pipeline construction proposed including:
d.
excavation widths and bedding depths appropriate to native soil types and
bedding classes proposed.
e.
procedures for determining appropriate installation parameters.
f.
pipelaying and jointing techniques.
g.
bedding backfill and compaction procedures for each class of bedding material.
Details of the bedding materials required by the pipe manufacturer together with a
grading curve and/or sieve analysis of each in tabular form and the degree of
compaction to be achieved by the Contractor.
Testing procedures and details, with sketches, of the deflection measurement

apparatus.
Details of in-situ joint construction involving hand lay-up butt and wrapped joints.
Procedures for building the pipes into concrete structures, together with sketches
showing short lengths, concrete surround etc.
5.6.5
Tests for GRP Pipes

-
Tests include long term stiffness, deflection and creep, flexural test, hydrostatic
pressure, corrosion resistance, longitudinal and hoop tensile strength and impact
resistance. The external pressure resistance shall be determined in accordance with
ASTM 2924.
The results of type tests appropriate to the proposed products shall be used to
determine the properties of pipes.
Each type test shall have been carried out on
representative samples of the pipes or fittings to be used. If alterations are proposed to

the method of manufacture, pipe material or pipe design the manufacturer shall carry
out all the required type tests to the satisfaction of the Engineer.
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-
Quality control tests shall be carried out on raw materials (e.g., resins, aggregates,
glass) as well as on laminate specimens, and shall include but not be limited to visual
inspection, checking of dimension, pressure tests etc.
No product from any source shall be incorporated into the Works without the successful
completion of all type tests, including HDB, Strain Corrosion, Creep, and Impact Tests,
under the direct supervision of the Contractor and the Engineer or conducted by the
competent independent Authority to the satisfaction of the Engineer.
Table 5.3: Restrained Joints Pressure Ratings (GRP)

No.
1
Test
Visual Inspection
Standard.
ASTM D 2563 /
DIN 19565(*)
Freq.
100%
Dimensional Check
ASTM D 3567 /
DIN 19565(*)
100%
3
4
Water Absorption
Barcol Hardness
ASTM D 570
ASTM D 2583
1%
100%
5
6
Loss on Ignition
Initial Longitudinal Unit
Tensile Strength by
Strip or Beam
Hoop Tensile Strength
Joint Tightness
ASTM D 2584
BS 5480,
Appendix A or B /
DIN 16869, Part II
(*)
ASTM D 2990 / D
1599
ASTM D 4161
Hydrostatic Pressure
BS 5480,
Appendix K
10
BS 5480,
Appendix H,
Method B
11
Initial Specific Stiffness

and Resistance to
Structural Damage
Under Ring Deflection
Impact Resistance
12
13
Creep
External Pressure
BS 5480,
Appendix J
DIN 16869
ASTM D 2924
14
Strain Corrosion
ASTM D 3681
15
Hydrostatic Design
Basic
ASTM D 2992,
Procedure B
16
Specific Ring Stiffness

and Creep Factor
BS 5480,
Appendix L
RI4326-D905-R3-0021
4%
1%
Remarks
Acceptance level-II (Table 1),
ends shall be sealed with 2 layers
Vinyl Ester Resin
Make a series of at least four
readings, approximately equally
spaced and within 5% accuracy
Part 1, Table 2-18
Min. 35 and/or 90% of resin
manufacturers declared value
Liner, structural wall and overall
Acceptance Range Table 2
1%
For pressure pipes only
1%
Tests shall be conducted in

straight, misaligned and in shear
loading conditions
10% for
gravity
100% for
pressure
pipelines
4%
1%
1%
1 / six
months
One set / 3
years or at
the change
of the raw
material
source
Page 30 of 44
All types of pipes
Controlled at temperature of 40
C for minimum one set of tests
consisting of 18 testing
specimens
specimens
18 October 2007
BAHRAIN BAY
No.
17
Test
Under Ring Deflection
(Creep)
Chemical Resistance
(Alkaline Environment)
Standard.
Freq.
ASTM D 3262
Remarks
specimens
specimens under pH12
Chemical Resistance Test (Strain Corrosion)

a.
Strain Corrosion tests for determining the chemical resistant properties of

fiberglass pipe in a deflection condition shall be carried out in accordance with
the appropriate standards.
b.
The procedure, medium and acceptance criteria for testing of GRP products shall
be accepted by the Engineer prior to commencement of tests.
c.
Tests shall be conducted in compliance with applicable and acceptable

standards and the failure strain applicable at 60 years shall be established. The
value shall not be less than or equal to 1%.
Dimensions
d.
An optical scale comparator with minimum 7 magnification having reticule

graduation with a 0.13 divisions shall be used for the measurements of the wall
thickness and liner thickness of products.
e.
A circumferential vemier wrap tape having an accuracy of +/- 0.4mm or a

micrometer caliper with an accuracy of +/- 0.25% shall be used for the
determination of average outer diameter (OD) of products.
f.
The length shall be measured with a steel tape or gauge having graduations of
1mm or less.
g.
The wall thickness, length, diameter and squareness of pipe ends shall be
measured for each pipe and fitting. The dimensions shall not deviate from the
tolerances specified.
Stiffness
h.
At least one pipe out of each batch of 30 pipes (or less), shall be tested to
determine the initial specific stiffness.
i.
In addition, each test specimen shall be deflected to amounts according to its

nominal stiffness. At the lower deflection there shall be no indication of structural
damage as evidenced by inter laminar separation, separation of the liner or
coating (if incorporated) from the structural wall, tensile failure of the glass fiber
reinforcement, fracture or buckling of the pipe wall.
j.
Specimens from pipes of 10,000 N/mm2, nominal initial stiffness shall be based
on:
k.
Min. 7% (Liner not to crack criteria)
RI4326-D905-R3-0021
Page 31 of 44
to DN < 200mm
18 October 2007
BAHRAIN BAY
l.
to DN > 200mm
m.
Min. 15% (Structural wall not to crack criteria)
to all DN
n.
Specimens from pipes of 5,000 N/mm2, nominal initial stiffness shall be based
on:
o.
to DN < 200mm
p.
q.
Min. 20% (Structural wall not to crack criteria)
r.
All percentages (%) deflection stated above are of the nominal diameter (DN).
to DN > 200mm
to all DN
Longitudinal Tensile Strength

s.
Longitudinal tensile strength of pipes shall be carried out as specified in the

appropriate standard. Tests shall be carried out on:
one pipe out 100 No's produced
for each diameter
for each class
Barcol Hardness
t.
A minimum of one pipe for every 30 pipes manufactured shall undergo a Barcol
hardness test in accordance with BS 4549: Part 1: Appendix A.
u.
v.
A minimum of one pipe of each class and diameter of pipe shall be tested,
The sample pipe shall also withstand a commercial acetone test on the internal
portion of the laminate.
Loss on Ignition
w.
A minimum of one pipe for every 30 pipes manufactured shall be tested in

accordance with EN 60 (Glass Reinforced Plastics; determination of the loss on
ignition) or ASTM D 2584 "Standard Method of Test for Ignition Loss of Cured
Reinforced Resins".
Joint Tests
x.
A minimum of two pipes out of 100 pipes shall be joined and tested subject to
the following:
The test pressure shall be as specified under hydraulic test.
An external test pressure of 1.0 bar (gauge) shall be applied to two sections of
pipe assembled with a deflected joint to check the water-tightness of the joint.
The deflection during the joint test shall be 1.5 for DN <600mm and 0.5 for DN
>600mm.
Visual Inspection
y.
Each pipe and fitting shall be subjected to a complete visual inspection before
shipment and after off loading at site.
Burst Test on Pressure Pipelines
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Page 32 of 44
18 October 2007
BAHRAIN BAY
z.
For pressure pipes a Burst Test shall be carried out in accordance with BS 5480
to determine the initial circumferential tensile strength of the pipe.
Failure of Tests
aa.
If any random test fails in any property then the batch from which the test sample
was taken shall be rejected and additionally 3 more random samples shall be
tested and if any one of these 3 fails the use of any batch of the tested product
shall be suspended and the Contractor shall submit evidence to the Engineers
satisfaction supporting further use of the product or an alternative in the Works.
5.6.6
Required Pipe Data
Table 5.4: Schedule Of GRP Pipe Data To Be Provided By Contractor
SCHEDULE OF GRP PIPE DATA TO BE PROVIDED BY CONTRACTOR

PIPE DATA
Manufacturing Details
Name of Manufacturer
Manufacturing process for pipes
Joint type
Manufacturing process for bends*
Summary of Design Criteria
Nominal internal Diameter
Class of Pipe
Minimum Depth of Cover
Maximum Depth of Cover
Maximum Working Pressure*
Test Pressure
Internal Vacuum Pressure*
Pipe Wall Structure
Nominal Total Wall Thickness
Inner Liner:
Thickness
Resin: Type
Veil: Glass Type
Structural Wall:
Resin: Type
Chopped Glass: Type
Hoop Glass: Type
Aggregate: Type
Minimum Initial Pipe Properties
Stiffness of Composite Section
Stiffness of Structural Section
Hoop Flexural Modulus of Composite Section of given thickness
Hoop Flexural Modulus of Structural Section of given thickness
Longitudinal Tensile Strength of Composite Section
Hoop Tensile Strength of Composite Section*
5.7
UNITS
mm
m
m
kN/m
kN/m
kN/m2
mm
mm
%
%
%
%
%
%
kN/m'
kN/m'
GN/m'
GN/m2
kN/m2
kN/m2
DUCTILE IRON PIPE AND FITTINGS

See section 5.2 for Foul and Storm Water Drainage Ductile Iron Pipe and Fittings
requirements.
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18 October 2007
BAHRAIN BAY
PIPE LAYING
6.1
GENERAL
Where socketed pipes are required to be laid on a granular or sand bed, or directly on a
trench bottom, joint holes shall be formed in the bedding material or final excavated surface to
ensure that each pipe is uniformly supported throughout the length of its barrel and to enable
the joint to be made.
Pipes shall be laid on setting blocks only where a concrete bed or cradle is used.
Where pipes are required to be bedded directly on the trench bottom, the final excavated
surface shall be trimmed and levelled to provide even bedding of the pipeline and shall be
free from all extraneous matter that may damage the pipe, pipe coating, or sleeving.
No protective cap, disc or other appliance on the end of a pipe or fitting shall be removed
permanently until the pipe or fitting which it protects is about to be jointed. Pipes and fittings,
including any lining or sheathing, shall be examined for damage and the joint surfaces and
components shall be cleaned immediately before laying.
Suitable measures shall be taken to prevent soil or other material from entering pipes, and to
anchor each pipe to prevent flotation or other movement before the Works are complete.
Where pipeline marker tape is specified, it shall be laid between 100 mm and 300 mm above
the pipe or as specified elsewhere in the Technical Specifications and Drawings.
Before any pipe is lowered into place, the bedding shall be prepared and well compacted so
that each length of pipe shall have a firm and uniform bearing over the entire length of the
barrel.
Pipe shall be laid in straight lines both in the horizontal and vertical planes, between
manholes or the placement of pipe shall comply with following requirements
-
Each pipe shall be plumbed to its correct line and directly and accurately sighted by
means of a laser positioning system or boning rods and sight rails fixed to secure posts
which shall be set up not more than 20 m apart.
Alternative methods of locating and leveling pipelines may be allowed subject to the
agreement of the Engineer.
Any pipe which is not in true alignment, both vertically and horizontally, or shows any undue
settlement after laying, shall be taken up and relaid correctly by the Contractor.
The trench shall be kept completely dry.
In no case shall pipes be jointed before being lowered into position.
The gasket should be positioned and lubricated prior to jointing.
The pipes shall be laid and bedded in granular bedding material except where concrete
bedding or protection is required. The granular material shall extend from not less than 150
millimetres beneath the pipes to 150 millimetres above the crown of the pipes or as directed
by the Engineer. Subsequent filling of the pipe trench shall be carried out as detailed in this
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18 October 2007
BAHRAIN BAY
Section of the Technical Specifications, as shown on the Drawings or as directed by the
Engineer.
GRP pipes shall, unless otherwise directed by the Engineer, be laid on a special bedding
material. The space below the barrel of the pipes shall be filled with special bedding material
to the full width of the trench in layers not exceeding 150mm in thickness. After pipe laying,
between the pipe and the undisturbed sides of the trench up to a depth of 150 mm above the
top of the pipe. The minimum thickness of the special bedding below the barrel of the pipe
shall be 250 mm or as directed by the Engineer. Where a manufacturer requires greater
thickness of special bedding below, around and over the pipes than those specified herein the
manufacturers requirements shall be deemed to have been allowed for in the rates for
bedding.
Where GRP pipes are built into a rigid structure; e.g., manhole or a pumping station, the first
100mm of pipe at entry to the structure shall be surrounded by an agreed flexible material.
Flexible joints shall be incorporated adjacent to structures
Where short GRP pipes are detailed these shall be factory made. Cut ends shall be sealed
with two layers of resin, the second layer being paraffin wax filled to ensure full cure.
Where GRP pipes are required to surrounded with concrete, all necessary precautions shall
be taken to ensure that maximum allowable deflections are not exceeded.
6.2
PIPE BEDDING
Bedding for pipes shall be constructed by spreading and compacting granular bedding
material over the full width of the pipe trench. After the pipes have been laid, additional
material shall, if required, be placed and compacted equally on each side of the pipes, and
where practicable, this shall be done in sequence with the removal of the trench supports.
6.3
CONCRETE PROTECTION TO PIPES

Pipes to be bedded on or cradled with concrete shall be supported on precast concrete
setting blocks. The top face of each block shall be covered with two layers of compressible
packing complying with BS 743.
Concrete provided as a protection to pipes shall be Grade C20, placed to the required depth
in one operation.
Where pipes with flexible joints are used, concrete protection shall be interrupted over its full
cross-section at each pipe joint by a shaped compressible filler of bitumen impregnated
insulating board to BS 1142 or equally compressible material.
The thickness of the
compressible filler shall be in accordance with Table 6.1.
Table 6.1: Thickness of Compressible Filler

Nominal bore of pipe (mm)
Less than 450
450 to 1200
RI4326-D905-R3-0021
Thickness of compressible filler (mm)

18
36
Page 35 of 44
18 October 2007
BAHRAIN BAY
Nominal bore of pipe (mm)
Exceeding 1200
Thickness of compressible filler (mm)

54
Rapid hardening cement shall not be used in concrete for the protection of plastics pipe.
Plastics pipes shall be wrapped with a layer of plastic sheeting complying with a composition
in accordance with Clause 3 of BS 6076 and a nominal thickness of 125 microns before being
surrounded by concrete.
6.4
COMPLETETION OF PIPE SURROUND

Fill material shall, where required, be placed and compacted over the full width of the trench
in layers not exceeding 150 mm before compaction, to a finished thickness of 250 mm above
the crown of the pipes.
6.5
BACKFILLING
Backfilling shall, wherever practicable, be undertaken immediately the specified operations
preceding it have been completed. Backfilling shall not, however, be commenced until the
works to be covered have achieved a strength sufficient to withstand all loading imposed
thereon.
Backfilling around existing structures shall be undertaken in such manner as to avoid uneven
loading or damage.
Filling material to excavations shall be deposited in layers not exceeding 250mm
unconsolidated thickness and compacted to 95% modified dry density.
Where the excavations have been supported and the supports are to be removed, these,
where practicable, shall be withdrawn progressively as backfilling proceeds in such a manner
as to minimise the danger of collapse. All voids formed behind the supports shall be carefully
filled and compacted.
6.6
GULLIES AND DRAINAGE CHANNELS
6.6.1
Gullies
Gullies shall incorporate rodding eyes. Rodding eyes shall be fitted with rubber stoppers
during normal operation.
All gullies shall be trapped to prevent unwanted odours escaping from the drain.
All gullies shall in corporate aluminium silt buckets.
The Contractor shall ensure that the gully outlet and the outlet pipework are compatible.
Gully covers, gratings and frames shall comply with the relevant provisions of BS 497: Part I
or BS EN I24.
The class of gullies covers, gratings and frames shall be as described in the Project
Specification or as shown on the Project Drawings.
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18 October 2007
BAHRAIN BAY
6.6.2
Pre-formed Gullies
Precast concrete gullies shall comply with the relevant provisions of BS 5911: Part 2.
Vitrified clay gullies shall comply with the relevant provisions at BS EN 295: Part I or BS 65.
Polypropylene gullies shall be of a type detailed in the Project Specification or shown on the
Project Drawings and shall be obtained from a reputable manufacturer as agreed with the
Engineer.
Cast iron gullies shall be of a type detailed in the Project Specification or shown on the Project
Drawings and shall be obtained from a reputable manufacturer as agreed with the Engineer.
Pre-formed gullies shall be bedded and surrounded with Grade C20 concrete to the thickness
described in the Contract Documentation.
Frames shall be bedded in mortar on two courses of Class B engineering brickwork or precast
concrete gully cover slabs. Precast concrete gully cover slabs shall comply with the relevant
provisions of BS 59 II: Part 2.
6.6.3
Manhole
The Contractor shall prepare a standard record sheet for every manhole and structure for
inclusion with the as-built drawings.
Manholes shall be constructed as shown on the contract Drawings and at the locations
indicated thereon or at such other locations directed by the Engineer.
The blinding concrete shall be mass concrete Grade 20SRC and shall be protected with
membrane tanking systems. The necessary period for setting, as recommended by the
manufacturer, shall be allowed before beginning other works to complete the construction of
the manhole.
The cover slabs shall be surmounted by cast iron manhole covers and frames of the quality
specified. The covers in roads and paved areas shall be accurately set on precast concrete
brickwork to the level and slopes of the roads or pavements.
In the case of shallow manholes, the cover and frame may be cast directly monolithic with the
reinforced concrete cover slab and projecting up by 50 mm as shown on the Contract
Drawings.
The interior face of manholes and access shafts shall be prefabricated GRP liners at least
6mm thick permanent lining.
Benchings and channels shall be preformed, inverted and filled with concrete. Alternatively,
the GRP lining may be applied in-situ after constructing the benching.
GRP Lining to walls shall incorporate lugs moulded onto the outside face at 500 mm centres
to allow bonding to the concrete surround. The lining shall have adequate strength to
withstand handling and shall not buckle or distort during pouring of the concrete surround.
Internal bracing may be used during pouring to maintain circularity and verticality.
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18 October 2007
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Precast cover slabs shall incorporate a performed flat sheet of GRP on the soffit, bonded to a
circular GRP tube to form the access opening. Both linings shall incorporate lugs moulded
onto the surface to allow bonding to the concrete.
Joints in the lining tubes shall not be permitted.
Joints between preformed GRP benchings and lining tubes shall be made using an external
sleeve 200 mm long bonded onto both units, and then bandaged using suitable resign and
chopped strand mat.
IF GRP linings to benchings are to be formed in situ the surface of the wall lining tube shall be
lightly abraded over a height of 150 mm from benching level. A fillet of 50 mm radius shall
then be formed of vinyl ester paste at the junction of benching and wall.
Top surface of benchings shall incorporate silica sand to form a non- slip surface.
The precast cover slab shall be seated on the walls using sand/cement mortar. The joint shall
be raked out 15mm deep on the inside face and pointed with an acceptable pitch extended
polyurethane sealant.
The Contractor shall provide the Engineer with a 7 year unconditional guarantee against
failure of all GRP linings whether caused by defective materials or workmanship. The
guarantee shall be valid from the date of completion of the installation and must be delivered
to the Engineer before the issue of the Final Completion Certificate.
All manholes shall be watertight on completion and where leakage is discovered the
Contractor shall perform such work and provide all materials as are necessary to render such
faulty work watertight. The Contractor is warned that he shall preclude rubbish and debris
being deposited in the manholes during the course of construction and he shall take the
necessary measures to ensure that the manhole is kept clean both during construction and
after completion.
Back filling around manholes in roads shall be carried out using granular material as directed
by the Engineer.
Step iron if shown on the Drawings shall comply with the relevant provisions of BS 497: Part 1
and have a minimum clear opening of 600 mm diameter if circular or 600 x 750 mm if
rectangular. All covers shall have closed key ways.
6.7
CONNECTION TO GOVERNMENT MAIN
6.7.1
General Requirements
Connection to government mains shall be done at manholes. Pipe saddles and oblique
junctions will not be permitted.
Where possible and practicable, connections shall be made to future connection ports in
existing Government manholes. The caps on future connection ports to which connections are
made shall be cleaned and delivered to the government stores on completion of the work.
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Where it is not possible or practicable to utilise future connection ports in existing manholes,
connections shall be made by either breaking into existing manholes or constructing new
manholes on existing mains.
If it is necessary to break into an existing manhole, the Contractor shall break into the
manhole wall, insert pipework, break out the existing benching, construct benching to suit new
connection and make good. If necessary, the Contractor shall relocate the access ladder and
the cover slab to suit the new benching layout .
Manholes built on an existing Government mains shall be constructed in accordance with the
relevant Authorities requirements or to the requirements of the technical Specifications,
whichever is the more stringent, but all to the approval of the relevant Authority. On
completion, such manholes shall become the property of the Government.
The Contractor shall be responsible for all over-pumping operations associated with making
connections to Government mains.
6.8
THRUST BLOCKS
Though standard drawings indicate typical thrust block details the Contractor should ensure
the proposed thrust blocks will be capable of handling the maximum system operating
pressure during the system performance period. All details of the thrust blocks shall be
submitted by the Engineer by way of shop drawings prior to commencement of construction.
Ductile Iron Pipes have specific requirements for thrust blocks and these should be referred to
above.
6.9
VALVES
6.9.1
General
Valves shall be capable of withstanding corrosion in the ambient conditions.
Nylon or other thermoplastic materials liable to attack shall not be used where hydrogen
sulphide is likely to be present.
All valve waterways shall be coated internally with a solvent free epoxy or polyester lining of
100% solid content to be applied at the place of manufacture. The lining shall be of 250
micron nominal thickness and holiday free.
All valves will normally be witness tested at works.
Unless otherwise specified all valves and penstocks shall be anti-clockwise opening and the
maximum effort required, applied at the circumference of the hand wheel to operate the
valves against the maximum unbalanced head shall not exceed 55kg.
All hand wheels shall have the words "to open" and "to close" in Arabic and English with
arrows indicating the direction of rotation cast on and shall be coated in plastic, nylon or other
acceptable materials in order to withstand the ambient conditions.
Unless otherwise specified or agreed spindles and extension spindles shall be of stainless
steel Grade 316 S16.
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Extension spindles, where required, shall be connected by suitable muff type couplings
manufactured from stainless steel grade 315S16. The muff couplings shall be supplied drilled
with nuts and bolts for connection to the spindles.
A clear polycarbonate tube shall be securely fitted to protect the thread of rising spindles.
The nuts shall be of gunmetal or synthetic material and mating surfaces of gates and bodies
shall be of gunmetal, copper alloy or synthetic material.
All fixing brackets, bolts and nuts, washers, etc. shall be SS grade 316 S16.
Where "Operation by Tee Key" is specified the valve or penstock shall be supplied with a
suitable yoke with a squared cap of standard size to receive the tee key.
The key shall be supplied at the rate of one key per two valves or two penstocks unless the
valve or penstock is to be installed in an isolated location in which case one key shall be
supplied for each fitting location.
Before delivery to site all working surfaces shall be thoroughly cleaned, and, if metal,
protected by grease.
Packing must be sufficient to ensure complete protection of the fitting during transit and
storage.
Valves under 300 mm diameter together with all hand wheels and other easily detachable
items on both valves and penstocks are to be packed in timber packing cases and properly
bound with steel packing bands.
All valves of 300 mm and over are to be protected with wood or plywood discs or flanges
together with straw rope and hessian wrapping.
6.9.2
Check Valves
Check valves three inches (3") and above shall be double flanged single door swing type
having ductile iron body and gunmetal seat to BS1400 .Pressure Rating to be PN 16 or more.
All valves shall be coated with electrostatically applied (at 2250C) epoxy internally and
externally to average DFT 300 microns for protection against corrosion of body components.
All nut bolts to be of stainless steel grade 316/ A4-70.
Check valves of two inches (2") and smaller shall be spring type manufactured from Brass or
Bronze. Inlet and outlet to be BSP female threaded. The spring shall be of stainless steel.
Pressure rating shall be PN16 or more.
The face to face lengths of the valves shall be either 2 x ND + 100 mm or to an agreed
international standard, the longer length to be allowed for in all cases using make up pieces
where necessary to achieve the required lengths.
All valves shall be clearway, and lugs provided on screwed seats, etc., for assembly purposes
shall be removed.
Sewerage valves shall, unless impracticable through size or otherwise specified shall be
capable of passing 90 mm dia. solids.
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6.9.3
Gate Valves
Gate valves shall conform to the requirements of the WDD and SDD Standard Specifications.
6.9.4
Air Valves
Air valves shall conform to the requirements of the WDD and SDD Standard Specifications
and the following requirements.
-
Automatic double orifice air vents shall be provided at all high points on the system. Air
valves and other similar items shall confirm to BS 2591. Automatic air valves shall have
non-corrosive floats in chambers with clear space ensuring blockage free operation. All
components for the air valve actuating mechanism including lever shall be stainless
steel.
The body and cover of the valve should be of bronze or ductile iron with phenolic primer
coating. Nozzles with seals and actuating mechanism to be located in the removable
upper plate connected to the valve body using stainless steel (grade 316/A4) bolts.
Valves shall be coated with epoxy internally and externally to average DFT 300 microns
for protection against corrosion of body components. All nut bolts to be of stainless
steel grade 316/ A4-70.
Unless higher pressure ratings are required for the pipeline, or otherwise indicated in
the Contract Documentation air valves shall have a nominal pressure rating of 10 bar
which shall be marked on the valve body and shall be designed for a liquid temp. of
500C and air temperature of 700C.
Air valves for pumped pressure pipelines shall be the high pressure Dual large orifice type.
The following shall be used as a guide for the general sizing of large orifice air valves:
Table 6.2: Sizing of Large Orifice Air Valves

Pipeline Bore (mm)
200
300
350
450
600
900
1000*
Air Valve size (mm)
20
25
50
80
100
150
200
100
100
100/125 100/125
125
125/200
Ball size (mm)
* For larger mains air valves may be fitted in clusters of two or more as required.
150/200
For mains 100mm diameter or less single, small orifice type standard air valves having a
nominal 25mm male thread inlet and with a ball size of 100 mm shall be used.
The test pressure for different components of the air valves shall be as follows:
Body
20 bar
Seat
10 bar
Ball/Float
10 bar
The materials of construction for air valves shall be as follows :Body, Cover & Duct Cover:
Ball/Guide:
Seat:
Air Release Nipple:
RI4326-D905-R3-0021
Cast Iron to agreed international Standard

Polypropylene
Nitrile Rubber
Moulded Rubber
Page 41 of 44
18 October 2007
BAHRAIN BAY
All Bolts:
Stainless Steel, Grade 316 S16
All components shall be highly resistant to corrosion due to sewage and very high
concentrations of H2S and other gases. All internal components shall be strong in design and
of stainless steel grade 316 S16.
The access cover for air valves shall be in such a position that the valves could be easily
removed for repair/maintenance.
The siting of the air valves shall be at locations shown on the Drawings or as directed by the
Engineer on site.
6.9.5
Penstocks
Fixings shall be of the drilled anchor type and made of stainless steel.
All penstocks shall be suitable for an on/off seating head of 10m minimum but in all instances
shall be less than 1.5 the maximum working head.
The size of the penstock to be used in any particular location shall be as described in the
Contract Documentation and agreed with the Engineer.
The frame, doors, sealing faces and spindles of each type shall be as specified in the
appropriate clauses herein.
Unless otherwise described in the Contract Documentation all penstocks shall be provided
with hand wheels of adequate diameter with suitable gearing where necessary to ensure that
the required operating force applied by hand does not exceed 55 kg.
Hand wheels shall have the words To Open and To Close in Arabic and English with arrows
indicating the direction of rotation cast on them. The direction of closing shall be clockwise
and a vandal / weatherproof, clear polycarbonate tube cover shall be securely fitted to the
thread of rising spindles. The tube shall be clearly and permanently engraved to indicate the
position of the penstock.
Spindles shall have machine cut robust trapezoidal or square form threads as necessary.
They shall be of stainless steel. Extension spindle coupling shall be of the muff type and they
shall be drilled and provided with a stainless steel nut and bolt for securing the spindle to the
penstock spindle head which likewise be drilled to take the bolt.
All penstocks shall be of the rising type unless otherwise stated. Headstock shall be provided
except in cases where the handwheels can be mounted on the penstock frames. Unless
otherwise stated for penstocks of 300mm (square or circular) or more thrust tubes shall be
provided. For all motorised/actuator operated penstocks thrust tubes shall be provided
between the penstock frame and headstock in order to absorb the thrust in both directions of
operation. Thrust tubes shall incorporate all necessary fixing brackets and spindle guide
plates.
Permissible rates of leakage under specified working head shall be as follows:
-
On seating installation: 5 litres per meter of slide perimeter per hour.
Off seating installation: 30 litres per meter of slide perimeter per hour.
RI4326-D905-R3-0021
Page 42 of 44
18 October 2007
BAHRAIN BAY
The slide perimeter shall be measured as the total length of contact faces between the gate
and frame in the closed position.
All materials used in the manufacture of penstocks shall conform to international standards
agreed with the Engineer if not otherwise specified.
6.9.6
Stainless Steel Penstocks

The frames and doors shall be of Grade 316 S31. The design of the doors shall be such that
the required working pressures can be withstood without deflection or distortion that would
affect the operation of the penstocks. Any strengthening of doors by the provision of ribs and
gussets shall be carried out by welding and not by bolting.
The side sealing faces may consist of simple metal to metal contact between the door and
frames or by synthetic rubber seals and plastic guides as necessary to withstand the required
working pressure without leakages.
Spindle shall be manufactured in stainless steel Grade 316 S31.
RI4326-D905-R3-0021
Page 43 of 44
18 October 2007
BAHRAIN BAY
End of Specification
RI4326-D905-R3-0021
Page 44 of 44
18 October 2007

Water Distribution and Controls

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Water Distribution and Controls

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Bahrain Bay Infrastructure

JOB NUMBER: RI4326

DOCUMENT REF: RI4326-D905-R3-0021

TRENCHES AND OTHER EXCAVATION

MATERIALS, PRODUCT DATA AND EQUIPMENT SCHEDULE

SHOP DRAWINGS AND VERIFICATION OF DIMENSIONS

Pipes and Fittings

RECOMMENDATION OF THE MANUFACTURERS

INSTALLATIONS AND TESTING

PRODUCT STORAGE AND HANDLING

TRANSPORTATION AND HANDLING

STORAGE AND HANDLING

PIPE WORKS GENERAL REQUIREMENTS

MATERIALS TO BE FURNISHED BY THE CONTRACTOR

POTABLE & IRRIGATION PIPES AND FITTINGS

High Density Polyethylene Pipe

PIPELINE PRESSURE TESTING

FOUL & STORM DRAINAGE PIPES AND FITTINGS

HANDLING AND STORAGE

UNIPLASTICISED POLYVINYL CHLORIDE (uPVC) PIPE AND FITTINGS

GLASS REINFORCED PIPE (GRP) & FITTINGS

DUCTILE IRON PIPE AND FITTINGS

CONCRETE PROTECTION TO PIPES

COMPLETETION OF PIPE SURROUND

GULLIES AND DRAINAGE CHANNELS

CONNECTION TO GOVERNMENT MAIN

Stainless Steel Penstocks

Potable Water and Fire Fighting

TRENCHES AND OTHER EXCAVATION

MATERIALS, PRODUCT DATA AND EQUIPMENT SCHEDULE

This shall include but not limited to the following

Manufacturer s installation instructions for all items.

Maintenance requirements and procedures.

Period of guarantee for products.

SHOP DRAWINGS AND VERIFICATION OF DIMENSIONS

Procedures for building pipes into concrete structures.

Procedures for encasing pipes in concrete.

Procedures for placing and fixing manhole covers and frames.

All other miscellaneous details required for complete installation.

Pipes and Fittings

Valves and Special Fittings

RECOMMENDATION OF THE MANUFACTURERS

commissioning of each material or piece of equipment prior to commencing work.

INSTALLATIONS AND TESTING

PRODUCT STORAGE AND HANDLING

It does not include machinery and equipment used for preparation,

fabrication, conveying and erection of the Works.

Products may also include existing

materials or components required for re-use.

TRANSPORTATION AND HANDLING

STORAGE AND HANDLING

PIPE WORKS GENERAL REQUIREMENTS

MATERIALS TO BE FURNISHED BY THE CONTRACTOR

Table 4.1: Pipe Material Schedule

Pipe Dia (mm)

300 and below

All pipe and appurtenances connected to equipment shall be supported in such a

Excavation and Backfilling

Underground Warning Tape

Table 4.2: Underground Warning Tape Requirements

POTABLE & IRRIGATION PIPES AND FITTINGS

High Density Polyethylene Pipe

Polyethylene pipes shall be High Density Polyethylene (HDPE) manufactured and