Base Build-Out, ANA Regional Brigade, Herat, Afghanistan AFHERATA

SECTION 02510

WATER DISTRIBUTION SYSTEM

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the

extent referenced. The publications are referred to in the text by basic
designation only.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM B 88 (1999) Seamless Copper Water Tube

ASTM B 88M (1999) Seamless Copper Water Tube (Metric)

ASTM D 1784 (1999a) Rigid Poly(Vinyl Chloride) (PVC)

Compounds and Chlorinated Poly(Vinyl
Chloride) (CPVC) Compounds

ASTM D 1785 (1999) Poly(Vinyl Chloride)(PVC) Plastic

Pipe, Schedules 40, 80, and 120

ASTM D 2241 (2000) Poly(Vinyl Chloride) (PVC)

Pressure-Rated Pipe (SDR Series)

ASTM D 2464 (1999) Threaded Poly(Vinyl Chloride) (PVC)

Plastic Pipe Fittings, Schedule 80

ASTM D 2466 (2001) Poly(Vinyl Chloride)(PVC) Plastic

Pipe Fittings, Schedule 40

ASTM D 2467 (2001) Poly(Vinyl Chloride) (PVC) Plastic

Pipe Fittings, Schedule 80

ASTM D 2564 (1996a) Solvent Cements for Poly(Vinyl

Chloride) (PVC) Plastic Piping Systems

ASTM D 2855 (1996) Making Solvent-Cemented Joints with

Poly(Vinyl Chloride) (PVC) Pipe and
Fittings

ASTM F 477 (1999) Elastomeric Seals (Gaskets) for

Joining Plastic Pipe

ASME INTERNATIONAL (ASME)

ASME B1.20.1 (1983; R 2001) Pipe Threads, General

Purpose, Inch

ASME B16.26 (1988) Cast Copper Alloy Fittings for

Flared Copper Tubes

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AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA B300 (1999) Hypochlorites

AWWA B301 (1999) Liquid Chlorine

AWWA C104 (2003) Cement-Mortar Lining for

Ductile-Iron Pipe and Fittings for Water

AWWA C110 (1993) Ductile-Iron and Gray-Iron

Fittings, 3 In. Through 48 In. (75 mm
through 1200 mm), for Water and Other
Liquids

AWWA C111 (2000) Rubber-Gasket Joints for

Ductile-Iron Pressure Pipe and Fittings

AWWA C115 (1996) Flanged Ductile-Iron Pipe With

Ductile-Iron or Gray-Iron Threaded Flanges

AWWA C151 (1996) Ductile-Iron Pipe, Centrifugally

Cast, for Water or Other Liquids

AWWA C153 (1994; Errata Nov 1996) Ductile-Iron

Compact Fittings, 3 In. Through 24 In. (76
mm through 610 mm) and 54 In. through 64
In. (1,400 mm through 1,600 mm) for Water
Service

AWWA C500 (1993; C500a) Metal-Seated Gate Valves for

Water Supply Service

AWWA C509 (1994; Addendum 1995) Resilient-Seated

Gate Valves for Water Supply Service

AWWA C600 (1993) Installation of Ductile-Iron Water

Mains and Their Appurtenances

AWWA C606 (1997) Grooved and Shouldered Joints

AWWA C800 (1989) Underground Service Line Valves and

Fittings

AWWA C900 (1997; C900a) Polyvinyl Chloride (PVC)

Pressure Pipe, 4 In. Through 12 In., for
Water Distribution

AWWA M23 (1980) Manual: PVC Pipe - Design and

Installation

BRITISH STANDARDS (BS)

BS 21 (1985) Specification for pipe threads for

tubes and fittings where pressuretight
joints are made on the threads (metric
dimensions)

BS 4772 (1988) Specification for ductile iron

pipes and fittings

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BS 5163 (1986) Specification for predominately

key-operated cast iron gate valves for
waterworks purposes

DEUTSCHES INSTITUT FUR NORMUNG (DIN)

DIN 3352 (1979) Gate Valves

DIN 8061 Unplasticized polyvinyl chloride pipes -

General quality requirements and testing

DIN 8062 Unplasticized polyvinyl chloride (PVC-U,

PVC-HI) pipes; dimenstions

DIN 8063 Pipe joints components of unplasticized

poly ()vinyl chloride) (PVC-U) for pipes
under pressure - Part 5: General quality
requirements, testing

DUCTILE IRON PIPE RESEARCH ASSOCIATION (DIPRA)

DIPRA TRD (1997) Thrust Restraint Design for Ductile

Iron Pipe

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 2531 (1998) Ductile iron pipes, fittings,

accessories and their joints for water or
gas applications

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-80 (1997) Bronze Gate, Globe, Angle and Check

Valves

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 49 (1994) Hazardous Chemicals Data

NFPA 325-1 (1994) Fire Hazard Properties of Flammable

Liquids, Gases, and Volatile Solids

NFPA 704 (1996) Identification of the Fire Hazards

of Materials for Emergency Response

1.2 PIPING

This section covers water distribution and service lines, and connections
to building service at a point approximately 1.5 m outside buildings and
structures to which service is required. The Contractor shall have a copy
of the manufacturer's recommendations for each material or procedure to be
utilized available at the construction site at all times.

1.2.1 Service Lines

Piping for water service lines less than 80 mm (3 inches) in diameter shall

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be polyvinyl chloride (PVC) plastic or copper tubing, unless otherwise

shown or specified. Piping for water service lines 80 mm (3 inches) and
larger shall be ductile iron, or polyvinyl chloride (PVC) plastic, unless
otherwise shown or specified.

1.2.2 Distribution Lines 80 mm (3 Inches) or Larger

Piping for water distribution lines 80 mm (3 inches) or larger shall be

ductile iron, or polyvinyl chloride (PVC), unless otherwise shown or
specified.

1.2.3 Excavation, Trenching, and Backfilling

Excavation, trenching, and backfilling shall be in accordance with the

applicable provisions of Section 02316 EXCAVATION, TRENCHING, AND
BACKFILLING FOR UTILITIES SYSTEMS, except as modified herein.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When
used, a designation following the "G" designation identifies the office
that will review the submittal for the Government. The following shall be
submitted in accordance with Section 01335 SUBMITTAL PROCEDURES:

SD-03 Product Data

Installation; G.

The manufacturer's recommendations for each material or

procedure to be utilized.

1.4 HANDLING

Pipe and accessories shall be handled to ensure delivery to the trench in

sound, undamaged condition, including no injury to the pipe coating or
lining. If the coating or lining of any pipe or fitting is damaged, the
repair shall be made by the Contractor in a satisfactory manner, at no
additional cost to the Government. No other pipe or material shall be
placed inside a pipe or fitting after the coating has been applied. Pipe
shall be carried into position and not dragged. Use of pinch bars and
tongs for aligning or turning pipe will be permitted only on the bare ends
of the pipe. The interior of pipe and accessories shall be thoroughly
cleaned of foreign matter before being lowered into the trench and shall be
kept clean during laying operations by plugging or other approved method.
Before installation, the pipe shall be inspected for defects. Material
found to be defective before or after laying shall be replaced with sound
material without additional expense to the Government. Rubber gaskets that
are not to be installed immediately shall be stored in a cool and dark
place.

1.4.1 Miscellaneous Plastic Pipe and Fittings

Polyvinyl Chloride (PVC) pipe and fittings shall be handled and stored in
accordance with the manufacturer's recommendations. Storage facilities
shall be classified and marked in accordance with NFPA 704, with
classification as indicated in NFPA 49 and NFPA 325-1 or equivalent DIN,
BS, or EN standards.

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PART 2 PRODUCTS

Where locally produced materials that meet requirements are available, use
these before imported materials.

2.1 PIPE

Pipe shall conform to the respective specifications and other requirements

specified below.

2.1.1 Plastic Pipe

2.1.1.1 PVC Plastic Pipe

Pipe, couplings and fittings shall be manufactured of material conforming

to ASTM D 1784, Class 12454B, ASTM D 1785, DIN 8061, DIN 8062, or DIN 8063.

Manufacturer: Egeplast, Akin, or Al Sharif.

a. Pipe Less Than 100 mm (4 inch) Diameter:

(1) Screw-Joint: Pipe shall conform to dimensional requirements

of ASTM D 1785 Schedule 80 or DIN 8061 (16 bar), with joints
meeting requirements of 1.03 MPa (150 psi) working pressure, 1.38
MPa (200 psi) hydrostatic test pressure, unless otherwise shown
or specified. Pipe couplings when used, shall be tested as
required by ASTM D 2464 or DIN 8063.

(2) Elastomeric-Gasket Joint: Pipe shall conform to dimensional

requirements of ASTM D 1785 Schedule 40, DIN 8062, or DIN 8061 (16
bar), with joints meeting the requirements of 1.03 MPa (150 psi)
working pressure, 1.38 MPa (200 psi) hydrostatic test pressure,
unless otherwise shown or specified, or it may be pipe conforming
to requirements of ASTM D 2241 or equivalent DIN, BS, or EN
standards, elastomeric joint, with the following applications:

Maximum Working Minimum Hydrostatic

SDR Pressure Pressure
MPa MPa
_____ _______________ ___________________

17 1.034 1.379

(3) Solvent Cement Joint: Pipe shall conform to dimensional

requirements of ASTM D 1785 or ASTM D 2241, DIN 8062, or DIN 8061
(16 bar) with joints meeting the requirements of 1.03 MPa (150
psi) working pressure and 1.38 MPa (200 psi) hydrostatic test
pressure.

b. Pipe 100 through 300 mm Diameter: Pipe, couplings and fittings

shall conform to AWWA C900, Class 150, CIOD pipe dimensions,
elastomeric-gasket joint, DIN 8062, or DIN 8061 (16 bar), unless
otherwise shown or specified.

2.1.2 Ductile-Iron Pipe

Ductile-iron pipe shall conform to AWWA C151 or BS 4772, working pressure

not less than 1.03 MPa (150 psi), unless otherwise shown or specified.
Pipe shall be cement-mortar lined in accordance with AWWA C104. Linings

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shall be standard. When installed underground, pipe shall be encased with

8 mil thick polyethylene in accordance with AWWA C105. Flanged ductile
iron pipe with threaded flanges shall be in accordance with AWWA C115.

2.1.3 Copper Tubing

Copper tubing shall conform to ASTM B 88, Type K, annealed or equivalent

DIN, BS, or EN standards.

2.2 FITTINGS AND SPECIALS

2.2.1 PVC Pipe System

a. For pipe less than 100 mm (4 inch) diameter, fittings for

threaded pipe shall conform to requirements of ASTM D 2464,
threaded to conform to the requirements of ASME B1.20.1 for use
with Schedule 80 pipe and fittings or equivalent DIN, BS, or EN
standards; fittings for solvent cement jointing shall conform to
ASTM D 2466 or ASTM D 2467 or equivalent DIN, BS, or EN standards;
and fittings for elastomeric-gasket joint pipe shall be iron or
PVC bell end conforming to AWWA C110, AWWA C111, or DIN 8063.
Iron fittings and specials shall be cement-mortar lined (standard
thickness) in accordance with AWWA C104.

b. For pipe 100 mm (4 inch) diameter and larger, fittings and

specials shall be iron or PVC, bell end in accordance with AWWA
C110 or DIN 8063, 1.03 MPa (150 psi) pressure rating unless
otherwise shown or specified, except that profile of bell may have
special dimensions as required by the pipe manufacturer; or
fittings and specials may be of the same material as the pipe with
elastomeric gaskets, all in conformance with AWWA C900 or
equivalent DIN, BS, or EN standards. Iron fittings and specials
shall be cement-mortar lined (standard thickness) in accordance
with AWWA C104. Fittings shall be bell and spigot or plain end
pipe, or as applicable. Ductile iron compact fittings shall be in
accordance with AWWA C153.

Manufacturer: Egeplast, Akin, or Al Sherif.

2.2.2 Ductile-Iron Pipe System

Fittings and specials shall be suitable for 1.03 MPa (150 psi) pressure
rating, unless otherwise specified. Fittings and specials for mechanical
joint pipe shall conform to AWWA C110 or BS 4772. Fittings and specials
for use with push-on joint pipe shall conform to AWWA C110, AWWA C111, BS
4772 or ISO 2531 or equivalent DIN, BS, or EN standards. Fittings and
specials for grooved and shouldered end pipe shall conform to AWWA C606 or
equivalent DIN, BS, or EN standards. Fittings and specials shall be
cement-mortar lined (standard thickness) in accordance with AWWA C104 or
equivalent DIN, BS, or EN standards. Ductile iron compact fittings shall
conform to AWWA C153 or equivalent DIN, BS, or EN standards.

Products: Dresser Piping Specialties; Style 138 and Style 162, or

Kubota.

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2.3 JOINTS

2.3.1 Plastic Pipe Jointing

2.3.1.1 PVC Pipe

Joints, fittings, and couplings shall be as specified for PVC pipe. Joints
connecting pipe of differing materials shall be made in accordance with the
manufacturer's recommendations, and as approved by the Contracting Officer.

Manufacturer: Egeplast, Akin, or Al Sharif.

2.3.2 Copper Tubing System

Fittings and specials shall be flared and conform to ASME B16.26 opr
equivalenr DIN, BS, or EN standards.

2.3.3 Ductile-Iron Pipe Jointing

a. Mechanical joints shall be of the stuffing box type and shall

conform to AWWA C111 or BS 4772.

b. Push-on joints shall conform to AWWA C111 or BS 4772.

c. Rubber gaskets and lubricants shall conform to the applicable

requirements of AWWA C111 or BS 4772.

2.3.4 Isolation Joints

Isolation joints shall be installed between nonthreaded ferrous and

nonferrous metallic pipe, fittings and valves. Isolation joints shall
consist of a sandwich-type flange isolation gasket of the dielectric type,
isolation washers, and isolation sleeves for flange bolts. Isolation
gaskets shall be full faced with outside diameter equal to the flange
outside diameter. Bolt isolation sleeves shall be full length. Units
shall be of a shape to prevent metal-to-metal contact of dissimilar
metallic piping elements.

a. Sleeve-type couplings shall be used for joining plain end pipe

sections. The two couplings shall consist of one steel middle
ring, two steel followers, two gaskets, and the necessary steel
bolts and nuts to compress the gaskets.

b. Split-sleeve type couplings may be used in aboveground

installations when approved in special situations and shall
consist of gaskets and a housing in two or more sections with the
necessary bolts and nuts.

2.3.5 Copper Tubing Jointing

Joints shall be compression-pattern flared and shall be made with the

specified fittings.

2.4 VALVES

2.4.1 Gate Valves

Gate valves shall be designed for a working pressure of not less than 1.03
MPa (150 psi). Valve connections shall be as required for the piping in

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which they are installed. Valves shall have a clear waterway equal to the
full nominal diameter of the valve, and shall be opened by turning
counterclockwise. The operating nut or wheel shall have an arrow, cast in
the metal, indicating the direction of opening.

a. Valves smaller than 80 mm (3 inches) shall be all bronze and

shall conform to MSS SP-80, Type 1, Class 150, DIN 3352, BS 21, or
ASME B1.20.1.

b. Valves 80 mm (3 inches) and larger shall be iron body, bronze

mounted, and shall conform to AWWA C500, DIN 3352, or BS 5163.
Flanges shall not be buried. An approved pit shall be provided
for all flanged connections.

c. Resilient-Seated Gate Valves: For valves 80 to 300 mm (3 to 12

inches) in size, resilient-seated gate valves shall conform to
AWWA C509, DIN 3352 or BS 5163.

d. Manufacturer: Use PN-10 Çakir Sürgülü Vana (Çakir Gate Valve) by

Çakir Vana; Waterworks Valve, Jafan or Tozen.

2.4.2 Vacuum and Air Relief Valves

Vacuum and air relief valves shall be of the size shown and shall be of a
type that will release air and prevent the formation of a vacuum. The
valves shall automatically release air when the lines are being filled with
water and shall admit air into the line when water is being withdrawn in
excess of the inflow. Valves shall be iron body with bronze trim and
stainless steel float.

2.4.3 Pressure Reducing Valves

Pressure reducing valves shall maintain a constant downstream pressure

regardless of fluctuations in demand. Valves shall be suitable for 1.03
MPa operating pressure on the inlet side, with outlet pressure set for
0.50 MPa. The valves shall be of the hydraulically-operated, pilot
controlled, globe or angle type, and may be actuated either by diaphragm or
piston. The pilot control shall be the diaphragm-operated, adjustable,
spring-loaded type, designed to permit flow when controlling pressure
exceeds the spring setting. Ends shall be flanged. Valve bodies shall be
bronze, cast iron or cast steel with bronze trim. Valve stem shall be
stainless steel. Valve discs and diaphragms shall be synthetic rubber.
Valve seats shall be bronze. Pilot controls shall be bronze with stainless
steel working parts.

2.5 VALVE BOXES

Valve boxes shall be cast iron or concrete, except that concrete boxes may
be installed only in locations not subjected to vehicular traffic.
Cast-iron boxes shall be extension type with slide-type adjustment and with
flared base. The minimum thickness of metal shall be 5 mm. Concrete boxes
shall be the standard product of a manufacturer of precast concrete
equipment. The word "WATER" shall be cast in the cover. The box length
shall adapt, without full extension, to the depth of cover required over
the pipe at the valve location.

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2.6 MISCELLANEOUS ITEMS

2.6.1 Service Clamps

Service clamps shall have a pressure rating not less than that of the pipe
to be connected and shall be either the single or double flattened strap
type. Clamps shall have a galvanized malleable-iron body with cadmium
plated straps and nuts. Clamps shall have a rubber gasket cemented to the
body.

2.6.2 Corporation Stops

Corporation stops shall have standard corporation stop thread conforming to

AWWA C800 or equivalent DIN, BS, or EN standards on the inlet end, with
flanged joints, compression pattern flared tube couplings, or wiped joints
for connections to goosenecks.

Product: Red Hed Manufacturing Company; Figure 4382, or equal.

2.6.3 Goosenecks

Copper tubing for gooseneck connections shall conform to the applicable

requirements of ASTM B 88M , Type K, annealed or equivalent DIN, BS, or EN
standards. Length of cable requirement connections shall be in accordance
with standard practice.

2.6.4 Service Stops

Service stops shall be water-works inverted-ground-key type, oval or round

flow way, tee handle, without drain. Pipe connections shall be suitable
for the type of service pipe used. All parts shall be of bronze with
female iron-pipe-size connections or compression-pattern flared tube
couplings, and shall be designed for a hydrostatic test pressure not less
than 1.375 MPa (200 psi).

Product: Red Hed Manufacturing Company; Figure 4161, or equal.

2.6.5 Tapping Sleeves

Tapping sleeves of the sizes indicated for connection to existing main

shall be the cast gray, ductile, or malleable iron, split-sleeve type with
flanged or grooved outlet, and with bolts, follower rings and gaskets on
each end of the sleeve. Construction shall be suitable for a maximum
working pressure of 1.03 MPa. Bolts shall have square heads and hexagonal
nuts. Longitudinal gaskets and mechanical joints with gaskets shall be as
recommended by the manufacturer of the sleeve. When using grooved
mechanical tee, it shall consist of an upper housing with full locating
collar for rigid positioning which engages a machine-cut hole in pipe,
encasing an elastomeric gasket which conforms to the pipe outside diameter
around the hole and a lower housing with positioning lugs, secured together
during assembly by nuts and bolts as specified, pretorqued to 67.8 Newton
meters (50 foot-pound).

Product: Dresser Piping Specialties; Style 91.

2.6.6 Service Boxes

Service boxes shall be cast iron or concrete and shall be extension service
boxes of the length required for the depth of the line, with either screw

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or slide-type adjustment. The boxes shall have housings of sufficient size

to completely cover the service stop or valve and shall be complete with
identifying covers.

2.6.7 Disinfection

Chlorinating materials shall conform to the following:

Chlorine, Liquid: AWWA B301.

Hypochlorite, Calcium and Sodium: AWWA B300.

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Cutting of Pipe

Cutting of pipe shall be done in a neat and workmanlike manner without

damage to the pipe. Unless otherwise recommended by the manufacturer and
authorized by the Contracting Officer, cutting shall be done with an
approved type mechanical cutter. Wheel cutter shall be used when
practicable. Copper tubing shall be cut square and all burrs shall be
removed. Squeeze type mechanical cutters shall not be used for ductile
iron.

3.1.2 Adjacent Facilities

3.1.2.1 Sewer Lines

Where the location of the water pipe is not clearly defined in dimensions
on the drawings, the water pipe shall not be laid closer horizontally than
3 m from a sewer except where the bottom of the water pipe will be at
least 300 mm above the top of the sewer pipe, in which case the water pipe
shall not be laid closer horizontally than 1.8 m from the sewer. Where
water lines cross under gravity-flow sewer lines, the sewer pipe, for a
distance of at least 3 m each side of the crossing, shall be fully encased
in concrete or shall be made of pressure pipe with no joint located within
900 mm horizontally of the crossing. Water lines shall in all cases cross
above sewage force mains or inverted siphons and shall be not less than 600
mm above the sewer main. Joints in the sewer main, closer horizontally
than 900 mm to the crossing, shall be encased in concrete.

3.1.2.2 Water Lines

Water lines shall not be laid in the same trench with sewer lines, gas
lines, fuel lines, or electric wiring.

3.1.2.3 Nonferrous Metallic Pipe

Where nonferrous metallic pipe, e.g. copper tubing, crosses any ferrous
piping material, a minimum vertical separation of 300 mm shall be
maintained between pipes.

3.1.2.4 Structures

Where water pipe is required to be installed within 1 m of existing

structures, the water pipe shall be sleeved as required in Paragraph
"Casing Pipe". The Contractor shall install the water pipe and sleeve

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ensuring that there will be no damage to the structures and no settlement

or movement of foundations or footings.

3.1.3 Joint Deflection

3.1.3.1 Offset for Flexible Plastic Pipe

Maximum offset in alignment between adjacent pipe joints shall be as

recommended by the manufacturer and approved by the Contracting Officer,
but shall not exceed 5 degrees.

3.1.3.2 Copper Tubing Requirements

Joints shall be made with flared fittings. The flared end tube shall be
pulled tightly against the tapered part of the fitting by a nut which is
part of the fitting, so there is metal-to-metal contact.

3.1.3.3 Allowable for Ductile-Iron Pipe

The maximum allowable deflection shall be as given in AWWA C600. If the

alignment requires deflection in excess of the above limitations, special
bends or a sufficient number of shorter lengths of pipe shall be furnished
to provide angular deflections within the limit set forth.

3.1.4 Placing and Laying

Pipe and accessories shall be carefully lowered into the trench by means of
derrick, ropes, belt slings, or other authorized equipment. Water-line
materials shall not be dropped or dumped into the trench. Abrasion of the
pipe coating shall be avoided. Except where necessary in making
connections with other lines or as authorized by the Contracting Officer,
pipe shall be laid with the bells facing in the direction of laying. The
full length of each section of pipe shall rest solidly upon the pipe bed,
with recesses excavated to accommodate bells, couplings, and joints. Pipe
that has the grade or joint disturbed after laying shall be taken up and
relaid. Pipe shall not be laid in water or when trench conditions are
unsuitable for the work. Water shall be kept out of the trench until
joints are complete. When work is not in progress, open ends of pipe,
fittings, and valves shall be securely closed so that no trench water,
earth, or other substance will enter the pipes or fittings. Where any part
of the coating or lining is damaged, the repair shall be made by and at the
Contractor's expense in a satisfactory manner. Pipe ends left for future
connections shall be valved, plugged, or capped, and anchored, as shown.

3.1.4.1 Plastic Pipe Installation

PVC pipe shall be installed in accordance with AWWA M23.

3.1.4.2 Piping Connections

Where connections are made between new work and existing mains, the
connections shall be made by using specials and fittings to suit the actual
conditions. When made under pressure, these connections shall be installed
using standard methods as approved by the Contracting Officer.

3.1.4.3 Penetrations

Pipe passing through walls of valve pits and structures shall be provided
with ductile-iron or Schedule 40 steel wall sleeves. Annular space between

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walls and sleeves shall be filled with rich cement mortar. Annular space
between pipe and sleeves shall be filled with mastic.

3.1.4.4 Flanged Pipe

Flanged pipe shall only be installed above ground or with the flanges in
valve pits.

3.1.5 Jointing

3.1.5.1 PVC Plastic Pipe Requirements

a. Pipe less than 100 mm (4 inch) diameter: Threaded joints shall

be made by wrapping the male threads with approved thread tape or
applying an approved lubricant, then threading the joining members
together. The joint shall be tightened using strap wrenches to
prevent damage to the pipe and/or fitting. To avoid excessive
torque, joints shall be tightened no more than one thread past
hand-tight. Preformed rubber-ring gaskets for elastomeric-gasket
joints shall be made in accordance with ASTM F 477 or equivalent
DIN, BS, or EN standards and as specified. Pipe ends for push-on
joints shall be beveled to facilitate assembly and marked to
indicate when the pipe is fully seated. The gasket shall be
prelubricated to prevent displacement. The gasket and ring groove
in the bell or coupling shall match. The manufacturer of the pipe
or fitting shall supply the elastomeric gasket. Couplings shall
be provided with stops or centering rings to assure that the
coupling is centered on the joint. Solvent cement joints shall
use sockets conforming to ASTM D 2467 or equivalent DIN, BS, or EN
standards. The solvent cement used shall meet the requirements of
ASTM D 2564 or equivalent DIN, BS, or EN standards; the joint
assembly shall be made in accordance with ASTM D 2855 or
equivalent DIN, BS, or EN standards and the manufacturer's
specific recommendations.

b. Pipe 100 through 300 mm diameter: Joints shall be elastomeric

gasket as specified in AWWA C900 or equivalent DIN, BS, or EN
standards. Jointing procedure shall be as specified for pipe less
than 100 mm (4 inch) diameter with configuration using
elastomeric ring gasket.

c. Pipe 350 through 900 mm diameter: Joints shall be elastomeric

gasket push-on joints made in accordance with AWWA M23 or
equivalent DIN, BS, or EN standards.

3.1.5.2 Ductile-Iron Pipe Requirements

Mechanical and push-on type joints shall be installed in accordance with

AWWA C600 for buried lines or AWWA C606 for grooved and shouldered pipe
above ground or in pits.

3.1.5.3 Isolation Joints and Dielectric Fittings

Isolation joints and dielectric fittings shall be installed in accordance

with details specified in paragraph JOINTS. Dielectric unions shall be
encapsulated in a field-poured coal-tar covering, with at least 3 mm
thickness of coal tar over all fitting surfaces.

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3.1.5.4 Transition Fittings

Connections between different types of pipe and accessories shall be made

with transition fittings approved by the Contracting Officer.

3.1.6 Installation of Service Lines

Service lines shall include the pipeline connecting building piping to

water distribution lines to the connections with the building service at a
point approximately 1.5 m outside the building where such building service
exists. Where building services are not installed, the Contractor shall
terminate the service lines approximately 1.5 m from the site of the
proposed building at a point designated by the Contracting Officer. Such
service lines shall be closed with plugs or caps. All service stops and
valves shall be provided with service boxes. Service lines shall be
constructed in accordance with the following requirements:

3.1.6.1 Service Lines 50 mm (2 Inches) and Smaller

Service lines 50 mm (2 inches) and smaller shall be connected to the main

by a directly-tapped corporation stop or by a service clamp. A corporation
stop and a copper gooseneck shall be provided with either type of
connection. Maximum sizes for directly-tapped corporation stops and for
outlets with service clamps shall be as in TABLE I. Where 2 or more
gooseneck connections to the main are required for an individual service,
such connections shall be made with standard branch connections. The total
clear area of the branches shall be at least equal to the clear area of the
service which they are to supply.

TABLE I. SIZE OF CORPORATION STOPS AND OUTLET

Pipe Size Corporation Stops, Outlets w/Service

mm mm Clamps, mm
For Ductile-Iron Pipe Single & Double Strap
___________ _______________________ ______________________

80 -- 25

100 25 25

150 32 40

200 40 50

250 40 50

300 & larger 50 50

NOTE:

a. Service lines 40 mm (1-1/2 inches) and smaller shall have a

service stop.

b. Service lines 50 mm (2 inches) in size shall have a gate valve.

3.1.6.2 Service Lines Larger than 50 mm (2 Inches)

Service lines larger than 50 mm (2 inches) shall be connected to the main

by a tapped saddle, tapping sleeve and valve, service clamp or reducing

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tee, depending on the main diameter and the service line diameter, and
shall have a gate valve. Lines 80 mm (3 inches) and larger may use
rubber-seated butterfly valves as specified above, or gate valves.

3.1.7 Setting of Valves and Valve Boxes

3.1.7.1 Location of Valves

After delivery, valves, including those in hydrants, shall be drained to

prevent freezing and shall have the interiors cleaned of all foreign matter
before installation. Stuffing boxes shall be tightened and hydrants and
valves shall be fully opened and fully closed to ensure that all parts are
in working condition. Check, pressure reducing, vacuum, and air relief
valves shall be installed in valve pits. Valves and valve boxes shall be
installed where shown or specified, and shall be set plumb. Valve boxes
shall be centered on the valves. Boxes shall be installed over each
outside gate valve unless otherwise shown. Where feasible, valves shall be
located outside the area of roads and streets. Earth fill shall be tamped
around each valve box or pit to a distance of 1.2 m on all sides of the
box, or the undisturbed trench face if less than 1.2 m.

3.1.7.2 Location of Service Boxes

Where no curbing exists, service boxes shall be installed in accessible

locations, beyond the limits of street surfacing, walks and driveways.

3.1.8 Thrust Restraint

Plugs, caps, tees and bends deflecting 11.25 degrees or more, either
vertically or horizontally, on waterlines 100 mm (4 inches) in diameter or
larger, and fire hydrants shall be provided with thrust restraints. Valves
shall be securely anchored or shall be provided with thrust restraints to
prevent movement. Thrust restraints shall be either thrust blocks or, for
ductile-iron pipes, restrained joints.

3.1.8.1 Thrust Blocks

Thrust blocking shall be concrete of a mix not leaner than: 1 cement,

2-1/2 sand, 5 gravel; and having a compressive strength of not less than 14
MPa after 28 days. Blocking shall be placed between solid ground and the
hydrant or fitting to be anchored. Unless otherwise indicated or directed,
the base and thrust bearing sides of thrust blocks shall be poured directly
against undisturbed earth. The sides of thrust blocks not subject to
thrust may be poured against forms. The area of bearing shall be as shown
or as directed. Blocking shall be placed so that the fitting joints will
be accessible for repair. Steel rods and clamps, protected by galvanizing
or by coating with bituminous paint, shall be used to anchor vertical down
bends into gravity thrust blocks.

3.1.8.2 Restrained Joints

For ductile-iron pipe, restrained joints shall be designed by the

Contractor or the pipe manufacturer in accordance with DIPRA TRD.

3.2 HYDROSTATIC TESTS

Where any section of a water line is provided with concrete thrust blocking
for fittings or hydrants, the hydrostatic tests shall not be made until at
least 5 days after installation of the concrete thrust blocking, unless

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otherwise approved.

3.2.1 Pressure Test

After the pipe is laid, the joints completed, fire hydrants permanently
installed, and the trench partially backfilled leaving the joints exposed
for examination, the newly laid piping or any valved section of piping
shall, unless otherwise specified, be subjected for 1 hour to a hydrostatic
pressure test of 1.38 MPa. Water supply lines designated on the drawings
shall be subjected for 1 hour to a hydrostatic pressure test of 1.38 MPa.
Each valve shall be opened and closed several times during the test.
Exposed pipe, joints, fittings, hydrants, and valves shall be carefully
examined during the partially open trench test. Joints showing visible
leakage shall be replaced or remade as necessary. Cracked or defective
pipe, joints, fittings, hydrants and valves discovered in consequence of
this pressure test shall be removed and replaced with sound material, and
the test shall be repeated until the test results are satisfactory. The
requirement for the joints to remain exposed for the hydrostatic tests may
be waived by the Contracting Officer when one or more of the following
conditions is encountered:

a. Wet or unstable soil conditions in the trench.

b. Compliance would require maintaining barricades and walkways

around and across an open trench in a heavily used area that would
require continuous surveillance to assure safe conditions.

c. Maintaining the trench in an open condition would delay completion

of the project.

The Contractor may request a waiver, setting forth in writing the reasons
for the request and stating the alternative procedure proposed to comply
with the required hydrostatic tests. Backfill placed prior to the tests
shall be placed in accordance with the requirements of Section 02316
EXCAVATION, TRENCHING, AND BACKFILLING FOR UTILITIES SYSTEMS.

3.2.2 Leakage Test

Leakage test shall be conducted after the pressure tests have been
satisfactorily completed. The duration of each leakage test shall be at
least 2 hours, and during the test the water line shall be subjected to not
less than 1.38 MPa pressure. Water supply lines designated on the
drawings shall be subjected to a pressure equal to 1.38 MPa. Leakage is
defined as the quantity of water to be supplied into the newly laid pipe,
or any valved or approved section, necessary to maintain pressure within
34.5 kPa (5 psi) of the specified leakage test pressure after the pipe has
been filled with water and the air expelled. Piping installation will not
be accepted if leakage exceeds the allowable leakage which is determined by
the following formula:

L = 0.0001351ND(P raised to 0.5 power)

L = Allowable leakage in gallons per hour

N = Number of joints in the length of pipeline tested
D = Nominal diameter of the pipe in inches
P = Average test pressure during the leakage test, in psi gauge

Should any test of pipe disclose leakage greater than that calculated by
the above formula, the defective joints shall be located and repaired until

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Base Build-Out, ANA Regional Brigade, Herat, Afghanistan AFHERATA

the leakage is within the specified allowance, without additional cost to

the Government.

3.2.3 Time for Making Test

Except for joint material setting or where concrete thrust blocks

necessitate a 5-day delay, pipelines jointed with rubber gaskets,
mechanical or push-on joints, or couplings may be subjected to hydrostatic
pressure, inspected, and tested for leakage at any time after partial
completion of backfill. Cement-mortar lined pipe may be filled with water
as recommended by the manufacturer before being subjected to the pressure
test and subsequent leakage test.

3.2.4 Concurrent Hydrostatic Tests

The Contractor may elect to conduct the hydrostatic tests using either or
both of the following procedures. Regardless of the sequence of tests
employed, the results of pressure tests, leakage tests, and disinfection
shall be as specified. Replacement, repair or retesting required shall be
accomplished by the Contractor at no additional cost to the Government.

a. Pressure test and leakage test may be conducted concurrently.

b. Hydrostatic tests and disinfection may be conducted concurrently,

using the water treated for disinfection to accomplish the
hydrostatic tests. If water is lost when treated for disinfection
and air is admitted to the unit being tested, or if any repair
procedure results in contamination of the unit, disinfection shall
be reaccomplished.

3.3 BACTERIAL DISINFECTION

3.3.1 Bacteriological Disinfection

Before acceptance of potable water operation, each unit of completed

waterline shall be disinfected as specified. After pressure tests have
been made, the unit to be disinfected shall be thoroughly flushed with
water until all entrained dirt and mud have been removed before introducing
the chlorinating material. The chlorinating material shall be either
liquid chlorine, calcium hypochlorite, or sodium hypochlorite, conforming
to paragraph MISCELLANEOUS ITEMS. The chlorinating material shall provide
a dosage of not less than 50 ppm and shall be introduced into the water
lines in an approved manner. Polyvinyl Chloride (PVC) pipe lines shall be
chlorinated using only the above specified chlorinating material in
solution. The agent shall not be introduced into the line in a dry solid
state. The treated water shall be retained in the pipe long enough to
destroy all non-spore forming bacteria. Except where a shorter period is
approved, the retention time shall be at least 24 hours and shall produce
not less than 25 ppm of free chlorine residual throughout the line at the
end of the retention period. Valves on the lines being disinfected shall
be opened and closed several times during the contact period. The line
shall then be flushed with clean water until the residual chlorine is
reduced to less than 1.0 ppm. During the flushing period, each fire
hydrant on the line shall be opened and closed several times. From several
points in the unit, personnel from the Contractor's commercial laboratory
shall take at least 3 water samples from different points, approved by the
Contracting Officer, in proper sterilized containers and perform a
bacterial examination in accordance with state approved methods. The
commercial laboratory shall be certified by the state's approving authority

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Base Build-Out, ANA Regional Brigade, Herat, Afghanistan AFHERATA

for examination of potable water. The disinfection shall be repeated until

tests indicate the absence of pollution for at least 2 full days. The unit
will not be accepted until satisfactory bacteriological results have been
obtained.

3.4 CLEANUP

Upon completion of the installation of water lines, and appurtenances, all

debris and surplus materials resulting from the work shall be removed.

-- End of Section --

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