TECHNICAL SPECIFICATION

HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS

PART 1 GENERAL

1.1 SECTION DESCRIPTION

1.1.1 This specification includes but is not limited to high-density polyethylene PE-100 as
per IS:4984 1995 (ductile iron pipe size O.D) pressure pipe primarily intended for the
transportation of water and sewage either buried or above grade.
1.2 REFERENCES
1.2.1 AWWA C901 Polyethylene (PE) pressure Pipe & Tubing, ½ inch through 3 inch for
water
1.2.2 AWWA C906 Polyethylene (PE) pressure Pipe & Fittings, 4 inch through 63 inch for
water
1.2.3 ASTM D3035 Standard Spec for PE Pipe (DR-PR) Based on Controlled Outside
Diameter
1.2.4 ASTM D3261 Butt Heat Fusion PE Fittings for PE Pipe & Tubing
1.2.5 ASTM D3350 Standard Specification for PE Pipe & Fittings Materials
1.2.6 ASTM D1238 Melt Flow Index
1.2.7 ASTM D1505 Density of Plastics
1.2.8 ASTM D2837 Hydrostatic Design Basis
1.2.9 NSF Std.#14 Plastic Piping Components & Related Materials
1.2.10 TR-33/2005 Generic Butt Fusion Joining Procedure for Field Joining of PE Pipe

1.3 GENERAL
1.3.1 USE
1.3.1.1 High Density Polyethylene (HDPE) pipes/fittings shall be allowed for use
as water, wastewater and reclaimed water pressure pipe where compatible
with the specific conditions of the project. The use of material other than
HDPE pipe may be required by HPCL/MECON if it is determined that
HDPE pipe is unsuitable for the particular application. All material used
in the production of water main piping shall be approved by the National
Sanitation Foundation (NSF).

1.4 DOCUMENTATION
1.4.1 Documentation from the resin’s manufacturer showing results of
the following tests for resin identification:
1.4.1.1 Melt Flow Index ASTM D1238
1.4.1.2 Density ASTM D1505

1.5 MANUFACTURER
1.5.1 All HDPE pipe and fittings shall be from a single manufacturer, who is fully
experienced, reputable and qualified in the manufacture of the HDPE pipe to be
furnished. The pipe shall be designed, constructed and installed in accordance with the
best practices and methods and shall comply with these Specifications.
1.6 FINISHED PRODUCT EVALUATION
1.6.1 Production staff shall check each length of pipe produced for the items listed below.
The results of all measurements shall be recorded on production sheets, which
become part of the manufacturer’s permanent records.

1.6.1.1 Pipe in process shall be checked visually, inside and out

for cosmetic defects (grooves, pits, hollows, etc.)
1.6.1.2 Pipe outside diameter shall be measured using a
suitable periphery tape to ensure conformance with
ASTM F714 or ASTM D3035, whichever is
applicable.
1.6.1.3 Pipe wall thickness shall be measured at 12 equally
spaced locations around the circumference at both ends of
the pipe to ensure conformance with ASTM F714 or
ASTM D3035, whichever is applicable.
1.6.1.4 Pipe length shall be measured.
1.6.1.5 Pipe marking shall be examined and checked for accuracy.
1.6.1.6 Pipe ends shall be checked to ensure they are cut square and clean.
1.6.1.7 Subject inside surface to a “reverse bend test” to ensure the
pipe is free of oxidation (brittleness).
1.7 STRESS REGRESSION TESTING
1.7.1 The polyethylene pipe manufacturer shall provide certification that stress regression
testing has been performed on the specific polyethylene resin being utilized in the
manufacture of this product. This stress regression testing shall have been done in
accordance with ASTM D2837 and the manufacturer shall provide a product
supplying a minimum Hydrostatic Design Basis (HDB) of 1,600 psi as determined
in accordance with ASTM D2837.
1.8 COMPATIBILITY
1.8.1 Contractor is responsible for compatibility between pipe materials, fittings and
appurtenances.
1.9 WARRANTY
 1.9.1 The pipe MANUFACTURER shall provide a warranty against manufacturing defects
of material and workmanship for a period of ten years after the final acceptance of the
project by the OWNER. The MANUFACTURER shall replace at no expense to the
OWNER any defective pipe/fitting material including labor within the warranty
period.

PART 2 PRODUCTS

2.1 MATERIALS
2.1.1 Materials used for the manufacture of polyethylene pipe and fittings shall be made
from a PE high density polyethylene resin compound.

2.1.2 High Density Polyethylene (HDPE) pipe shall comply with AWWA Specifications
C906.

2.1.3 If rework compounds are required, only those generated in the Manufacturer’s own
plant from resin compounds of the same class and type from the same raw material
supplier shall be used.

2.1.4 Dimensions and workmanship shall be as specified by ASTM F714. HDPE fittings
and transitions shall meet ASTM D3261. HDPE pipe shall have a minimum density
of 0.955 grams per cubic centimeter. All HDPE pipe and fittings shall have a
Hydrostatic Design Basis (HDB) of 1,600 psi.

2.1.6 The pipe Manufacturer must certify compliance with the above requirements.

2.2 VOID
2.3 FITTINGS
2.3.1 All molded fittings and fabricated fittings shall be fully pressure rated to match the
pipe SDR pressure rating to which they are made. All fittings shall be molded or
fabricated by the manufacturer. No Contractor fabricated fittings shall be used unless
approved by the Engineer.

2.3.2 The manufacturer of the HDPE pipe shall supply all HDPE fittings and accessories as
well as any adapters and/or specials required to perform the work as shown on the
Drawings and specified herein.

2.3.3 All fittings shall be installed using butt-fused fittings, thermo-fused fittings/couplings,
or flanged adapters and must be approved by the Engineer. NO size on size wet taps
shall be permitted.

2.3.4 All transition from HDPE pipe to ductile iron or PVC shall be made per the approval
of HPCL/MECON and per the HDPE pipe manufacturer’s recommendations and
specifications. A molded flange connector adapter within a carbon steel back-up ring
assembly shall be used for pipe type transitions. Ductile iron back-up rings shall mate
with cast iron flanges per ANSI B16.1. A 316 stainless steel back-up ring shall mate
with a 316 stainless steel flange per ANSI B16.1.
 2.3.4.1 Transition from HDPE to ductile iron fittings and valves shall be approved by
HPCL/MECON before installation.

2.3.4.2 No solid sleeves shall be allowed between such material transitions.

2.3.4.3 Fittings and transitions shall be as manufactured by Phillips DRISCOPIPE, Inc.,

1000 Series Pressure Pipe, Chevron Chemical Company Plexco / Spiralite pipe,
or equal.

2.3.4.4 The pipe supplier must certify compliance with the above requirements.
2.4 PIPE IDENTIFICATION
2.4.1 The following shall be continuously indent printed on the pipe or spaced at
intervals not exceeding 5-feet:
2.4.1.1 Name and/or trademark of the pipe manufacturer.
2.4.1.2 Nominal pipe size.
2.4.1.3 Dimension ratio.
2.4.1.4 The letters PE followed by the polyethylene grade in accordance with
ASTM
2.4.1.5 D1248 followed by the hydrostatic design basis in 160’s of psi, e.g.,
PE 3408.
2.4.1.6 Manufacturing standard reference, e.g., ASTM F714 or D-3035, as
required.
2.4.1.7 A production code from which the date and place of manufacture can
be determined.
2.4.1.8 Colour Identification, either stripped by co-extruding longitudinal
identifiable colour markings or shall be solid in colour and as
follows:
i. BLUE – Potable Water

i. GREEN – Sanitary Sewer

2.4.2 Tracing Wire
2.4.2.1 Open trench installation of HDPE shall be identifiable per HPCL/MECON
Specification Sec. 02600, Part 2, 2.01 (A).
2.4.2.2 Directional Drilled HDPE shall have wire conforming to Copperhead
Industries Reinforced #1245 Extra-High Strength Tracer Wire and
affixed to the drilling head/reamer per Detail M-17.
2.4.3 Marking Tape: Marking tape shall be installed per HPCL/MECON approval.
PART 3 EXECUTION

3.1 JOINING METHOD

3.1.1 The pipe shall be joined with butt, heat fusion joints as outlined in ASTM D2657
and conform to the Generic Butt Fusion Joining Procedure for Field Joining of
Polyethylene Pipe, Technical Report TR-33/2005, published by the Plastic Pipe
Institute (PPI). All joints shall be made in strict compliance with the manufacturer’s
recommendations. A factory qualified joining technician as designated by pipe
manufacturer or experienced, trained technician shall perform all heat fusion joints
in the presence of the HPCL/MECON.
3.1.2 Lengths of pipe shall be assembled into suitable installation lengths by the butt-
fusion process. All pipes so joined shall be made from the same class and type of
raw material made by the same raw material supplier. Pipe shall be furnished in
standard laying lengths not to exceed 50 feet and no shorter than 20 feet.
3.1.3 On days butt fusions are to be made, the first fusion shall be a trial fusion in the
presence of a HPCL/MECON. The following shall apply:
3.1.3.1 Heating plate surfaces shall be inspected for cuts and scrapes and shall be free of
dirt and residue. Heater surfaces should be between 400OF (minimum) to 450OF
(maximum). Measure the temperature @ 12:00, 3:00, 6:00 and 9:00 o’clock
positions using a pyrometer of infrared thermometer at locations where the
heating plate will contact the pipe/fitting ends. The maximum temperature
difference between any two points on a single heating surface must not exceed
24OF. If this temperature is exceeded, the heating plate shall be cleaned per the
manufacturer’s recommendations.
3.1.3.2 The fusion or test section shall be cut out after cooling completely for
inspection.

3.1.3.3 The test section shall be 12” or 30 times (minimum) the wall thickness in length
and 1” or 1.5 times the wall thickness in width (minimum).

3.1.3.4 The joint shall be visually inspected as to continuity of “beads” from the melted
material, and for assurance of “cold joint” prevention (i.e. – joint shall have
visible molded material between walls of pipe). Joint spacing between the walls
of the two ends shall be a minimum of 1/16” to a maximum 3/16”.
3.1.4 The polyethylene flange adapters at pipe material transitions shall be backed up by
stainless steel flanges conforming to ANSI B16.1 and shaped as necessary to suit
the outside dimensions of the pipe. The flange adapter assemblies shall be
connected with corrosion resisting bolts and nuts of Type 316 Stainless Steel as
specified in ASTM A726 and ASTM A307. All bolts shall be tightened to the
manufacturer’s specified torques. Bolts shall be tightened alternatively and evenly.
After installation, apply a bitumastic coating to bolts and nuts.
PART 4 INSTALLATION

4.1 High Density Polyethylene (HDPE) Pipe shall be installed in accordance with the
instruction of the manufacturer, as shown on the Drawings and as specified herein.
A factory qualified joining technician as designated by the pipe manufacturer shall
perform all heat fusion joints.
4.2 HDPE shall be installed either by Open Trench Construction or Directional Bore
Method.
4.3 Care shall be taken in loading, transporting and unloading to prevent damage to the
pipe. Pipe or fitting shall not be dropped. All pipe or fitting shall be examined
before installation, and no piece shall be installed which is found to be defective.
Any damage to the pipe shall be repaired as directed by the Engineer. If any
defective pipe is discovered after it has been installed, it shall be removed and
replaced with a sound pipe in a satisfactory manner by the contractor, at his own
expense.
4.4 Under no circumstances shall the pipe or accessories be dropped into the trench or
forced through a directional bore upon “pull-back”.
4.5 Care shall be taken during transportation of the pipe such that it will not be cut,
kinked or otherwise damaged.
4.6 Ropes, fabric or rubber protected slings and straps shall be used when handling
pipes. Chains, cables or hooks inserted into the pipe ends shall not be used. Two
slings spread apart shall be used for lifting each length of pipe.
4.7 Pipes shall be stored on level ground, preferably turf or sand, free of sharp objects,
which could damage the pipe. Stacking of the polyethylene pipe shall be limited to
a height that will not cause excessive deformation of the bottom layers of pipes
under anticipated temperature conditions. Where necessary due to ground
conditions, the pipe shall be stored on wooden sleepers, spaced suitably and of such
width as not to allow deformation of the pipe at the point of contact with the sleeper
or between supports.
4.8 Pipe shall be stored on clean level ground to prevent undue scratching or gouging.
The handling of the pipe shall be in such a manner that the pipe is not damaged by
dragging it over sharp and cutting objects. The maximum allowable depth of cuts,
scratches or gouges on the exterior of the pipe is 5 percent of wall thickness. The
interior pipe surface shall be free of cuts, gouges or scratches.
4.9 Pipe shall be laid to lines and grade shown on the Drawings with bedding and
backfill as shown on the Drawings.
4.10 When laying is not in progress, including lunchtime, the open ends of the pipe shall
be closed by fabricated plugs, or by other approved means.
4.11 Sections of pipe with cuts, scratches or gouges exceeding 5 percent of the pipe wall
thickness shall be removed completely and the ends of the pipeline rejoined.
4.12 The pipe shall be joined by the method of thermal butt fusion. All joints shall be
made in strict compliance with the manufacturer’s recommendations.

4.13 Mechanical connections of the polyethylene pipe to auxiliary equipment such as

valves, pumps and tanks shall be through flanged connections which shall consists
of the following:
4.13.1 A polyethylene flange shall be thermally butt-fused to the stub end of the
pipe.
4.13.2 A 316 stainless steel back up ring shall mate with a 316 stainless steel
flange.
4.13.3 A 316 stainless steel bolts and nuts shall be used.

4.14 Flange connections shall be provided with a full-face neoprene gasket.

4.15 All HDPE pipe must be at the temperature of the surrounding soil at the time of
backfilling and compaction.

4.16 If a defective pipe is discovered after it has been installed, it shall be removed and
replaced with a sound pipe in a satisfactory manner at no additional cost to the
Owner. All pipe and fittings shall be thoroughly cleaned before installation, shall
be kept clean until they are used in the work and when laid, shall conform to the
lines and grades required. kinked or otherwise damaged.

4.17 Open Trench Installation:

4.17.1 HPCL/MECON Standards and Specification, Section 02200 – Utility Excavation,
Trenching, and Backfilling shall apply in its entirety. For proper laying excavation
of any kind of soil and strata including shoring work (where needed and so directed
by the Engineer-in-charge), dewatering of trenches by pumps, preparation of bed
(having no sharp and hard materials which can cause injury to the pipes and specials),
has to be done by contractor including removing of excavated earth at the safe
distance, as directed by the Engineer-in-charge. The depth of excavation shall be in
such a manner that a minimum clear cover of 600 MM is available from top of pipe
for filling. Lowering ·cleaning, laying and jointing of pipes and specials shall have
to be done as per methods already described. However, other precaution and measure
shall have to carry out as follows;
4.17.2 The centerline of the pipe shall not deviate from a straight line drawn between the
centers of the openings at the ends of the pipe by more than 1/16-in per foot of length.
If a piece of pipe fails to meet this requirement check for straightness, it shall be
rejected and removed from the site. Laying instructions of the manufacturer shall be
explicitly followed.

4.17.3 Good alignment shall be preserved during installation. Deflection of the pipe shall
occur only at those places on design drawings and as approved by the Engineer
Fittings, in addition to those shown on the Drawings, shall be used only if necessary
or required by the Engineer.
 4.17.4 Each length of the pipe shall have the assembly mark aligned with the pipe previously
laid and held securely until enough backfill has been placed to hold the pipe in place.
Joints shall not be “pulled” or “cramped”.
4.17.5 Precautions shall be taken to prevent flotation of the pipe in the trench.
4.17.6 When moveable trench bracing such as trench boxes, moveable sheeting, shoring or
plates are used to support the sides of the trench, care shall be taken in placing and
moving the boxes or supporting bracing to prevent movement of the pipe, or
disturbance of the pipe bedding and the backfill. Trench boxes, moveable sheeting,
shoring or plates shall not be allowed to extend below top of the pipe. As trench
boxes, moveable sheeting, shoring or plates are moved, pipe bedding shall be placed
to fill any voids created and the backfill shall be recompacted to provide uniform side
support for the pipe.

4.17.7 Restrained joints shall be installed where shown on the Drawings or as directed by
the Engineer.
4.18 Directional Bore Installation:
4.18.1 Refer to HPCL/MECON Specification 02320 - Horizontal Directional Drilling in its
entirety

PART 5 CLEANING

5.1 At the conclusion of the work, thoroughly clean all of the new pipe lines to remove all dirt,
stones, pieces of wood or other material which may have entered during the construction
period by forcing a cleaning swab through all mains 4” or greater. Flushing velocities shall
be a minimum of 2.5 feet per second. All flushing shall be coordinated with HPCL/MECON
and Water Resources Department. Debris cleaned from the lines shall
be removed from the job site.

PART 6 TESTING

6.1 Pressure testing shall be conducted per Manufacturer’s recommendations and as

approved by the HPCL/MECON.
6.2 All HDPE water mains shall be disinfected prior to pressure testing as per HPCL/MECON
specification.

6.3 All HDPE mains shall be field-tested. Contractor shall supply all labor, equipment,
material, gages, pumps, meters and incidentals required for testing. Each main shall be
pressure tested upon completion of the pipe laying and backfilling operations, including
placement of any required temporary roadway surfacing.
6.4 All mains shall be tested at 150 percent of the operating design pressure of the pipe
unless otherwise approved by the Engineer.
6.5 Pressure testing procedure shall be per Manufacturer’s recommendations or as follows:
6.5.1 Fill line slowly with water. Maintain flow velocity less than 2 feet per second.
6.5.2 Expel air completely from the line during filling and again before applying test pressure.
Air shall be expelled by means of taps at points of highest elevation.
6.5.3 Apply initial test pressure and allow to stand without makeup pressure for two to three
hours, to allow for diametric expansion or pipe stretching to stabilize.

6.5.4 After this equilibrium period, apply the specified test pressure and turn the pump off. The
final test pressure shall be held for one to three hours.

6.5.5 Upon completion of the test, the pressure shall be bled off from a location other than the
point where the pressure is monitored. The pressure drop shall be witnessed by the
resident project representative and HPCL/MECON representative at the point where the
pressure is being monitored and shall show on the recorded pressure read-out submitted
to the Engineer of Record.
6.6 Allowable amount of makeup water for expansion during the pressure test shall conform to
Chart 6, Allowance for Expansion Under Test Pressure, Technical Report TR 31/9-79,
published by the Plastic Pipe Institute (PPI). If there are no visual leaks or significant
pressure drops during the final test period, the installed pipe passes the test.
6.7 If any test of pipe laid disclosed leakage significant pressure drop greater than the
manufacturer’s recommended loss, the Contractor shall, at his/her own expense, locate and
repair the cause of leakage and retest the line. The amount of leakage, which will be
permitted, shall be in accordance with AWWA C600 Standards.
6.8 All visible leaks are to be repaired regardless of the amount of leakage.
6.9 The Contractor must submit his plan for testing to the Engineer for review at least 10
days before starting the test and shall notify HPCL/MECON inspector a minimum of 48
hours prior to test.