SECTION HIGH DENSITY POLYETHYLENE (HDPE) PRESSURE PIPE

Transcription

1 SECTION HIGH DENSITY POLYETHYLENE (HDPE) PRESSURE PIPE PART 1 - GENERAL 1.01 WORK INCLUDED High Density Polyethylene (HDPE) pressure pipe and fittings in sizes 1/2-inch through 63-inch. HDPE pipe shall be provided in iron pipe standard sizes (IPS) QUALITY ASSURANCE A. Reference Specifications: 1. AWWA C906: Polyethylene (PE) Pressure Pipe and Fittings, 4 inches through 63 inches, For Water Distribution. 2. AWWA C901 : Polyethylene Pressure Pipe and Tubing, 1/2-inch through 3 inch, for Water Service. 3. NSF Std #14: Plastic Piping Components and Rel_ted Materials. 4. ASTM D638: Test Method for Tensile Properties of Plastics. 5. ASTM D790: Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials. 6. ASTM D1238: Test Method for Flow Rates of Thermoplastics by Extrusion Plastometer. 7. ASTM F1473: Standard Test Method for Notch Tensile Test to Measure the Resistance to Slow Crack Growth of Polyethylene Pipes and Resins 8. ASTM D1505: Test Method for Density of Plastics by the Density-Gradient Technique. 9. ASTM D1598: Test Method for Time-to-Failure of Plastic Pipe Under Constant Internal Pressure 10. ASTM D1599: Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe, Tubing, and Fittings. 11. ASTM D1693: Test Method for Environmental Stress-Cracking of Ethylene Plastics. 12. ASTM D2122: Method for Determining Dimensions of Thermoplastic Pipe and Fittings. 13. ASTM D2837: Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials. 14. ASTM D3350: Specification for Polyethylene Plastics Pipe and Fittings Materials. 15. ASTM F1248: Test Method for Determination of Environmental Stress Crack Resistance (ESCR) of Polyethylene Pipe. 16. ASTM D4218: Test Method for Determination of Carbon Black Content in Polyethylene Compounds by the Muffle-Furnace Technique. 17. ASTM D2737: Specification for Polyethylene (PE) Plastic Tubing. 18. ASTM D2239: Specification for Polyethylene (PE) Plastic Pipe (SIDR-PR) Based on Controlled Inside Diameter

2 ASTM D3261: Butt Heat Fusion Polyethylene PE Plastic Fittings for Polyethylene PE Plastic Pipe and Tubing. ASTM F2206: Fabricated Fittings of Butt-Fused Polyethylene (PE) Plastic Pipe, Fittings, Sheet Stock, Plate Stock, or Block Stock. ASTM F1055: Electrofusion Type Polyethylene Fittings for Outside Diameter Controlled Polyethylene Pipe and Tubing. B. C. High Density Polyethylene (HDPE) pressure pipe and fittings may be rejected for failure to meet any of the requirements of this specification. Pipe rejected by the ENGINEER shall be removed from the site. Inspection: The quality of all materials, process or manufacture and the finished pipe shall be subject to the inspection and approval of the ENGINEER SUBMITTALS A. Submit shop drawings and product data in accordance with the requirements of Section B. Submit manufacturer's installation instructions. C. Submit affidavits of compliance with the referenced standards. NSF requirements only apply to potable water applications DELIVERY, STORAGE AND HANDLING A. Comply with the manufacturer's handling and storage recommendations. B. Use nylon slings or rope to lift bundles of pipe. Do not use chains. C. Do not drop pipe. D. Support pipe every 4 feet. E. Limit stacking height of pallets to prevent any undue stress or deflection in pipe materials. F. Manufacturer shall package the pipe in a manner designed to deliver the pipe to the project neatly, intact, and without physical damage. The transportation carrier shall use appropriate methods and intermittent checks to insure the pipe is properly supported, stacked, and restrained during transport such that the pipe is not nicked, gouged, or physically damaged. G. Pipe shall be stored on clean, level ground to prevent undue scratching or gouging of the pipe. If the pipe must be stacked for storage, such stacking shall be done in accordance with the pipe manufacturer's recommendations. The handling of the pipe shall be done in such a manner that it is not damaged by dragging over sharp objects or cut by chokers or lifting equipment

3 H. Sections of pressure pipe having been discovered with cuts or gouges in excess of 10 percent of the wall thickness of the pipe shall be cut out and removed. The undamaged portions of the pipe shall be rejoined using the heat fusion joining method. I. Fused segments of pipe shall be handled so as to avoid damage to the pipe. When lifting fused sections of pipe, chains or cable type chokers must be avoided. Nylon slings are preferred. Spreader bars are recommended when lifting long fused sections. Care must be exercised to avoid cutting or gouging the pipe. PART 2 - PRODUCTS 2.01 GENERAL A. Pressure pipe for potable water systems shall bear the seal of approval of the National Sanitation Foundation for use in potable water systems. B. All HDPE pipe shall be new and shall be marked as in Paragraph E below. C. Pressure pipe shall be as manufactured by Rinker Materials Polypipe or approved equal. D. The pipe shall have true section complying with the sizes specified. All pipe shall be free from cracks, holes, blisters, voids, projections, defects, roughness and chalking, sticky or tacky material. E. Injection molded and electrofusion fittings shall be as manufactured by Central Plastics Company or approved equal. Fabricated fittings shall be as manufactured by ISCO Industries or approved equal. Fittings shall have a minimum pressure rating equal to the pressure rating of the pipe it is attached to. F. Pipe and fittings must be marked as prescribed by AWWA C901 or C906 and NSF. Pipe markings will include nominal size, OD base (ie.: 12 inch iron pipe sizing, IPS), dimension ratio, pressure class, Working Pressure Rating (WPR), AWWA C901 or C906, manufacturer's name, manufacturer's production code including day, month, year extruded, and manufacturer's plant and extrusion line; and optional NSF-pw logo Material Materials used for the manufacture of polyethylene pipe and fittings shall be extra high molecular weight, high density ethylene/hexene copolymer PE C polyethylene resin as defined in ASTM meeting the above appropriate referenced specifications: The polyethylene pipe manufacturer shall provide certification that stress regression testing has been performed on the pipe product. The said certification shall include a stress life curve per ASTM D2837. The 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 (HOB) of 1,600 psi, as determined in accordance with ASTM D

4 Further, the material shall be listed by PPI (the Plastics Pipe Institute, a division of the Society of the Plastics Industry) in PPI TR-4 with a 73 F hydrostatic design stress rating of 1600 psi, and a 140 F hydrostatic design stress rating of 800 psi. The PPI Listing shall be in the name of the pipe manufacturer, and shall be based on ASTM D2837 and PPI TR-3 testing and validation of samples of the pipe manufacturer's production pipe. The manufacturer's certification shall state that the pipe was manufactured from one specific resin in compliance with these specifications. The certificate shall state the specific resin used, its source, and list its compliance to these specifications PIPE EXTRUSION The pipe shall be extruded using a melt homogenizing/plasticating extruder and "appropriate" die. The extruder screw design should be customized for the HDPE being processed. The extruded tubular melt will be vacuum or pressure sized in downstream cooling tanks to form round pipe to specification diameter and wall thickness with a "matt finish" surface, per AWWA C901 or C PIPE AND FITTINGS A. Pipe Pipe supplied under this specification shall have a nominal IPS (iron pipe size) OD unless otherwise specified. The SDR (Standard Dimension Ratio), and the pressure rating of the pipe supplied shall be as specified by Engineer. The pipe shall be produced from approved HDPE pipe grade resin(s) to the dimensions and tolerances specified in AWW A C901 or C906. Any pipe supplied for non-potable reuse water line shall be purple in color. The pipe for potable, sanitary sewer, and raw water lines shall be black in color. The pipe shall contain no recycled compound except that generated in the manufacturer's own plant from resin of the same specification from the same raw material. The pipe shall be homogenous throughout and free of visible cracks, holes, voids, foreign inclusions, or other deleterious defects, and shall be nominally identical in color, density, melt index, and other physical properties throughout. B. Pipe Performance The pipe shall be in compliance with the physical and performance requirements of applicable referenced specifications. Specifically, the pipe will be extruded from resin meeting specifications of ASTM D3350 with a cell classification of PE C. C. Fittings The HDPE fittings shall be standard commercial products. Provide fittings manufactured by injection molding if available, otherwise fittings shall be fabricated from C901 or C906 pipe conforming to this specification. All fittings shall be provided/recommended by the manufacturer of the pipe on each project. The fittings

5 shall be manufactured from the same resin type, grade, and cell classification as the pipe itself. The fittings shall be fully pressure rated by the manufacturer to provide a working pressure equal to the pipe. The manufacture of the fittings shall be in accordance with good commercial practice to provide fittings homogeneous throughout and free from cracks, holes, foreign inclusions, voids, or other injurious defects. The fitting shall be as uniform as commercially practicable in color, opacity, density, and other physical properties. The minimum "quick-burst" strength of the fittings shall not be less than that of the pipe with which the fitting is to be used. All fittings shall be pressure tested by the pipe/fitting manufacturer to the specification and requirements of AWW A C901 or C906. Standard fittings are tees, ells, wyes, 45 bends, flange adapters, reducers, transition fittings, branch and service saddles, and hot-tap tees REPAIR EQUIPMENT/SPARE PARTS The contractor shall supply the following HDPE pipe repair equipment to the City. All repair equipment and spare parts shall be new equipment. A. Furnish three (3) 500 kv portable AC generators with twist lock plugs. The power output must be continuous rating not peak rating. The generator shall be compatible with the processor provided. The generator shall have a one-year warranty. B. Furnish three (3) bar code Universal processors for use with an AC generator that can be used with electrofusion fittings from multiple suppliers. The processor shall have a primary voltage of 110 or 115 V AC with a frequency of Hertz and will operate from 0 to 120 F. The processor shall have a one-year warranty. The processor shall be as manufactured by Central or approved equal. C. Furnish three (3) of each size of HDPE scraper tool required for the pipe being provided on this project. Scraper shall be as manufactured by Central Plastics Company or approved equal. D. Furnish three (3) manual squeeze tools for 3" IPS HDPE pipe to shut off the flow in a pipe during repairs. Squeeze tool shall be as manufactured by McElroy or approved equal. E. Furnish 100 linear feet of each size and pressure rating of HDPE supplied in this project. Additional pipe furnished shall be from the same manufacturer as supplied for the rest of the project. F. Furnish a supply of spare parts equal to a minimum of 10 percent of the each size and type of fitting installed, with a minimum of one spare fitting of each size and type. Also provide 1 coupler for every 1000 LF of each size of HDPE being supplied. All fittings supplied as spare parts shall be of the electrofusion type. The pressure rating on the fittings and couplers shall be greater than or equal to the fittings or pipe being supplied. Electrofusion fittings shall be from the same manufacturer as supplied for the rest of the project. If electrofusion fittings are not used in the installed low pressure sewer system then fittings shall be from an engineer approved manufacturer

6 PART 3 - EXECUTION 3.01 INSTALLATION A. General: 1. Comply with the general requirements of these specifications and the supplemental requirements following. 2. Install all piping in accordance with pipe manufacturer's instructions. B. Making of Joints: Sections of polyethylene pipe should be joined into continuous lengths on the job site above ground. The joining method shall be by either the heat fusion or electrofusion method, and shall be performed in strict accordance with the pipe and fitting manufacturer's recommendations. 1. The heat fusion equipment used in the joining procedures should be capable of meeting all conditions recommended by the pipe manufacturer, including but not limited to, temperature requirements of 450 F, alignment, and 75 psi interfacial fusion pressure. Heat fusion joining shall be 100% efficient offering a joint weld strength equal to or greater than the tensile strength of the pipe. The fusion equipment operator shall receive training using the recommended procedure. The Contractor shall be responsible to verify that the fusion equipment is in good operating condition and that the operator has been trained with the past twelve months. 2. Polyethylene pipe and fittings may be joined using approved electrofusion couplings. Fittings shall be PE3408 HDPE, Cell classification of C as determined by ASTM Electrofusion fittings shall have a manufacturing standard of ASTM F1055. Fittings shall have a pressure rating equal to the pipe unless otherwise specified on the plans. All electrofusion fittings shall be suitable for use as pressure conduits, and per AWW A C906, have nominal burst values of three and one-half times the Working Pressure Rating (WPR) of the fitting. 3. Socket fusion, hot gas fusion, threading, solvents, and epoxies will not be used to join HDPE pipe. 4. Mechanical joining will be used where the butt fusion and electrofusion methods can not be used or where called out on plans. Mechanical joining will be accomplished by either using an HDPE flange adapter with a Ductile Iron back up ring or HDPE Mechanical Joint adapter with a Ductile Iron back-up ring. Flanges, unions, groovedcouplers, transition fittings and some mechanical couplers may be used to mechanically connect HDPE pipe without butt fusion. Refer to manufacturer's recommendations. 5. Plastic to Metal Connections: a. Make all plastic to metal connections by means of HDPE adapters. b. 00 not cut threads on HDPE Pipe. C. Buried Piping: 1. All excavation shall be done in an approved manner to the elevations and grades shown on the Plans or specified. The trench bottom shall be free of sharp rocks and large clods of dirt. 2. Embedment for HDPE pipe shall be as shown on the Plans: ASTM C33 #67 embedment under the pipe to a depth 0.75 o.d. (maximum 6") and initial backfill

7 to 6 inches over the pipe. All bedding and granular backfill material shall be consolidated to 85 percent standard proctor density. 3. Backfill shall be placed according to the contract documents. 4. Pipe shall be placed in trench so that the pipe forms a slight "S" curve in the trench to accommodate expansion and contraction of the HDPE material in accordance with the manufacturer's recommendations. D. Exposed Piping: 1. Where required HDPE piping shall be installed in the locations indicated with hangers, brackets, supports, etc., at spacings recommended by the pipe manufacturer. 2. Flexible connections shall be required at locations where pipe passes through a concrete wall FIELD TESTING Comply with the requirements of Section END OF SECTION

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