Sewerage Code of Australia: Second Edition

Sewerage Code of Australia
Part 2: Products and Materials

Second Edition
Version 2.3
WSA 022002-2.3
122
CONTENTS
10 PRODUCTS AND MATERIALS OVERVIEW
10.1 PURPOSE
10.2 SCOPE
10.3 RESPONSIBILITIES
10.3.1 Water Agency
10.3.2 Designer
10.3.3 Constructor
10.3.4 Purchaser
10.4 PRODUCT AND MATERIAL STANDARDS AND SPECIFICATIONS
10.4.1 Product standards
10.4.2 Purchase specifications
10.4.3 Purchase specificationsAlternatives
10.5 QUALITY ASSURANCE
10.5.1 Default requirement
10.5.2 Additional information on quality assurance
10.5.3 Innovative products and materials
10.6 SELECTION GUIDE FOR PIPELINE SYSTEMS
10.7 ADDITIONAL PRODUCT AND MATERIAL INFORMATION
APPENDIX F QUALITY ASSURANCE OF PRODUCTS AND MATERIALS

F1 GENERAL
F2 QUALITY ASSURANCE OPTIONS
F2.1 ISO 9000 quality management system certification
F2.2 Product certification
F2.2.1 Product certification Type 1
F2.3 Suppliers declaration of conformance
F2.4 Second party verification
F3 FACTORS INFLUENCING SELECTION OF QUALITY ASSURANCE OPTIONS
F3.1 General factors
F3.2 Likelihood of manufacturing non-conformance
F3.3 Likelihood of failure of pipeline system from a product non-conformance
F3.4 Consequences of failure
F3.5 Product specification
F3.6 Project magnitude / management
F3.7 Innovative products
F4 SELECTING THE QUALITY ASSURANCE OPTION
F4.2.1 General
F4.2.2 Type 1
F4.2.3 Type 3
F4.2.4 Type 5
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TABLES
TABLE 10.1 PRINCIPAL GRAVITY SEWER PIPELINE SYSTEMS
TABLE 10.2 PRINCIPAL SEWERAGE GRAVITY PIPELINE SYSTEMS - PRECAUTIONS,
LIMITATIONS ADVANTAGES AND DISADVANTAGES
TABLE 10.3 PRINCIPAL SEWERAGE PRESSURE PIPELINE SYSTEMS
TABLE 10.4 PRINCIPAL SEWERAGE PRESSURE PIPELINE SYSTEMS PRECAUTIONS, LIMITATIONS ADVANTAGES AND DISADVANTAGES
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WSA 022002-2.3
10 PRODUCTS AND MATERIALS OVERVIEW

10.1 PURPOSE
Water Agencies typically expect sewerage infrastructure to have a life of at least 100
years. This requirement reflects community expectations of Agencies operational and
financial performance. The performance of a sewer system significantly depends on the
attributes of the materials and products used in its construction. The appropriate selection
of pipeline system products and materials is paramount to achieving life expectancies.
NOTE: The term products and materials will simply be referred to as products from this point
forward since it could be argued that materials are in fact a subset of products.
Unless otherwise specified by the Water Agency, products should comply with recognised
national or industry standards. The involvement of third party certification bodies to
independently verify conformance is stipulated for many products.
The purpose of Part 2 is to:
(a)
provide information and recommendations concerning products to assist policymakers, planners, Designers, Constructors, manufacturers, suppliers and third party
certification bodies;
(b)
nominate default product standards; and
(c)
provide default purchase specifications for products.
Product and Material Information and Guidance and Purchase Specifications can be found
on the WSAA website at www.wsaa.asn.au.
This edition of WSA 02 does not include a "Product Atlas". For products that
have been formally appraised by WSAA, the website provides details of the
appraisal. The website does not provide a listing of approved products and
suppliers. Individual Agencies may operate their own product approval or
authorisation system.
10.2 SCOPE
This Part provides information, standards and purchase specifications for products
commonly used in sewer construction and listed on the WSAA website www.wsaa.asn.au.
Products may be added or deleted as the need arises. The WSAA website should be
accessed to ensure that current information is used.
10.3 RESPONSIBILITIES
10.3.1 Water Agency
Each Water Agency should be responsible for:
(a)
Accepting or excluding products listed in this Part as being suitable for use in its area
of responsibility.
(b)
Nominating variations to the default purchase specifications and quality assurance

requirements.
10.3.2 Designer
Except where a project or Agency agreement or specification states otherwise, the
Designer should be deemed responsible for selecting the most appropriate / suitable
products. In some cases, products may have to be authorised by the Water Agency.
Product requirements, including attributes such as protective coating, pressure and/or
stiffness class, joint type etc should be stated in the Design Drawings and/or Specification.
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10.3.3 Constructor
Constructors should use only such products that are nominated in the Specification and
Design Drawings.
10.3.4 Purchaser
Unless otherwise specified by the Water Agency, the default purchase specifications listed
on the WSAA website (Refer to Clause 10.4.2) should be used for specifying product
requirements.
The purchaser should be responsible for obtaining the suppliers declaration that products
conform to purchase specifications.
The Constructor is frequently the purchaser of products.
Where third party certification is specified, the accredited certification body is
deemed to be responsible for licensing the manufacturer to use the
certification bodys mark and ensuring correct use of the mark
The supplier may or may not be the manufacturer of the product.
10.4 PRODUCT AND MATERIAL STANDARDS AND SPECIFICATIONS
10.4.1 Product standards
A product standard is generally a document prepared by a standards body recognised
nationally, regionally or internationally such as Standards Australia, International
Organisation for Standardisation (ISO), European Committee for Standardisation (CEN) or
a water industry body such as PIPA, WRc (UK) or AWWA (USA). The standard typically
specifies product attributes such as dimensions, materials of construction, performance
requirements, production and factory quality control and product testing.
The product standard should be adopted as the technical specification for manufacture and
the reference for third-party certification of product conformance.
For most products used in the water industry, appropriate manufacturing standards exist.
These standards (including overseas standards) may be purchased from Standards
Australia.
If, at any time, a suitable product standard is not available to meet WSAA members needs,
WSAA may prepare and publish a product standard. This generally will be an interim
solution, pending publication of a suitable Australian standard. WSAA product standards
are listed on the WSAA website.
Examples of product standards are AS 2638.2Gate valves for waterworks purposes
Resilient seated; AS/NZS 1477PVC pipes and fittings for pressure applications;
BS EN 545Ductile iron pipes, fittings, accessories and their joints for water pipelines
Requirements and test methods; WSA 103Butterfly valves.
In some cases more than one product standard is deemed by this Code to be suitable for
use e.g. for ductile iron pipe, AS/NZS 2280 or BS EN 545 due to the availability of
acceptable products from overseas. Each Water Agency should be responsible for
nominating which options are acceptable for use.
10.4.2 Purchase specifications
Purchase specifications are the means for purchasers to specify their requirements to
suppliers. In most cases, the purchase specification references a relevant product standard
and nominates quality assurance requirements. The purchaser should nominate options
allowed by the product standard e.g. protective coatings, pressure class, stiffness class,
joint type etc.
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WSA 022002-2.3
WSAA purchase specifications are listed on the WSAA website.

Given that specifications are liable to change, users should regularly review the revision
status of specifications. The WSAA website contains a list of recent additions or variations
to specifications.
10.4.3 Purchase specificationsAlternatives
In some cases, typically for products of overseas origin, more than one product standard
has been deemed by WSAA to be applicable to a product type. A matching alternative
purchase specification (i.e. additional to the default) is listed on the website e.g. for ductile
iron pipes and fittings, alternative specification WSA 201 references EN 545.
Each Water Agency shall be responsible for nominating which alternative specification(s)
are acceptable.
Where more than one purchase specification is listed for a product (e.g. ductile iron), the
default specification shall be deemed to apply, unless otherwise specified by the Water
Agency.
WSAA product standards and purchase specifications are published by the
Water Services Association of Australia Inc. on the understanding that:
The Water Services Association of Australia Inc. and individual contributors are
not responsible for the results of any action taken on the basis of information in
the WSAA product standards and/or purchase specifications, nor any errors or
omissions.
The Water Services Association of Australia Inc. and individual contributors
disclaim all and any liability to any person in respect of anything, and the
consequences of anything, done or omitted to be done by a person in reliance
upon the whole or any part of a WSAA product standard or purchase
specification.
It should also be noted that WSAA product specifications have no reference to
any contractual requirements or general terms and conditions that may be
required by purchasers. Such contract details are the responsibility of the
individual purchaser.
10.5 QUALITY ASSURANCE
10.5.1 Default requirement
Unless otherwise specified by the Water Agency, the default quality assurance option
nominated in the product purchase specification should apply. Where third party
certification is specified, the certification body (CB) should be accredited by JAS-ANZ or by
an equivalent overseas accreditation body.
When placing an order, the purchaser should ensure that the supplier is aware of the
specified quality assurance requirement.
10.5.2 Additional information on quality assurance
Additional information concerning material and product quality assurance is given in
Appendix F.
10.5.3 Innovative products and materials
Innovative products are deemed to be those for which a recorded history of successful
performance under a range of Australian installation and operating conditions is not
available and for which a default or alternative specification is not included in this Code.
Depending on the outcomes of a product appraisal, such products may be recommended
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for provisional acceptance. Nevertheless, each Water Agency is responsible for authorising
innovative or non-standard products.
It is intended that the WSAA product appraisal process facilitate information
sharing and ultimate standardisation of innovative products.
The WSAA website displays reports of products which have been assessed by
the WSAA appraisal process as being suitable for use. Following satisfactory
appraisal, a purchase specification may be published on the website and the
product is thus no longer deemed to be innovative. Products assessed as
unsuitable for use are not published in the public domain, but referred to the
applicant for further action.
Disclaimer
The WSAA product appraisal process involves assessment of product
attributes and expected performance when installed in accordance with the
manufacturers or other nominated recommendations. Reasonable measures
are taken by the WSAA network to assess suitability for use in conditions
commonly encountered in Australia. However, responsibility for use of
appraised products and materials is the individual agencies, users or
specifiers.
To view the current disclaimer of liability for product appraisal refer to the
WSAA website.
10.6 SELECTION GUIDE FOR PIPELINE SYSTEMS

Tables 10.1 and 10.2 provide general information on availability of sizes, jointing and fitting
options and comparisons of principal pipeline options. The objective of this comparison is
to assist specifiers make informed decisions on material selection. Life cycle costing as per
AS/NZS 4536 should be considered as part of the decision making process. More detailed
information on products is provided on the WSAA website.
When in doubt, specialist advice should be obtained, including from the pipe manufacturer.
10.7 ADDITIONAL PRODUCT AND MATERIAL INFORMATION
Additional information on product attributes, uses, benefits and limitations is given on the
WSAA website. The information is not intended for use in a contractual sense but serves
as a guide to specifiers, Designers, Constructors and other interested parties.
Information will be updated in line with market developments and as further feedback on
product performance is received.
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WSA 022002-2.3
TABLE 10. 1
PRINCIPAL GRAVITY SEWER PIPELINE SYSTEMS
Informative
PIPE
CONVENTIONA
L
PIPE SIZES
TYPICAL PIPE
CLASSES
JOINTING
METHODS
FITTINGS
DN
Crushing strengths
DN 150 34 kN/m
VC
150, 225, 300,

400, 450, 500,
600, 700, 800,
1000
DN 200-250
Classes 160, 200
DN 300-350
Classes 120, 160, 200
DN 400-500
Classes 120, 160
Rubber ring seal

Polypropylene
couplings with
rubber lip seal
VC bends, junctions,
connectors and
adaptors
DN 600-1000
Classes 95, 120
PVC
Reinforced
concrete
(PVC lined)
GRP
100, 150, 225,

300, 375, 450
600, 750, 900,
1050, 1200,
1350, 1500,
1800, 2100
300, 375, 450,

525, 600, 675,
750, 900,
1000, 1200
SN 6 or 10 for DN 100
SN 4 or 8 for other sizes
Class 3
Class 4
PE
Solvent cement
weld
SN 5000
SN 10000
Rubber ring seal
GRP couplings
with rubber lip
seal
MHs, saddles for

slope and square
junctions, connectors
and other
configurations
available
SN 15000
SN 8
SN 10
Electrofusion fittings
DN 110 DN 450
Electrofusion
Butt fusion
SN 16
PVC bends, junctions,

connectors and
adaptors
Fittings not readily
available
Pipes with inlets,
bends and specials
manufactured to order
Stiffness classes
Stiffness classes
110, 125, 160,
180, 225, 280,
315, 450, 630
Rubber ring seal
PE plain end for butt

fusion and
electrofusion
Flanged fittings
Mechanical fittings
ABS
AS 3518
300,
400,
575,
750,
350, 375,
450, 500,
600, 650,
850
Stiffness and equivalent

pressure class
SN 6 ( PN 6.6)
SN 8 ( PN 7.3)
Rubber ring seal

Solvent cement
weld
SN 10 ( PN 7.8)
DI
Cement
mortar
lined
100,
225,
375,
600,
150, 200,
250, 300,
450, 500,
750
Pipe wall thickness

classes
Flanged fittings
Fabricated fittings for
larger diameters
Rubber ring seal
Ductile iron cement

mortar lined (DICL)
Flanged
Fusion bonded
polymer encapsulated
ductile iron
K9
K12 - flanged and
special structural design
Limited range of
fittings
NOTE: For special applications in large diameters, steel pipe lined with PE or high alumina cement
may be suitable.
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TABLE 10.2
PRINCIPAL SEWERAGE GRAVITY PIPELINE SYSTEMS
PRECAUTIONS, LIMITATIONS ADVANTAGES AND DISADVANTAGES
All pipelines may be damaged, rendered structurally unsound or have inadequate joint performance due to incorrect
installation practices
All pipes and fittings may be damaged prior to installation by inappropriate transportation, storage and handling practices
GENERAL
PRECAUTIONS
All pipelines should be constructed by trained and certified pipelayers with a system of documentation for quality control of
installation in place
All pipelines can be adversely affected in both the short and long term by third party damage to the pipe or corrosion
protection system
All pipes require verification of the internal diameter for hydraulic designthe nominal size does not necessarily represent
accurately the internal diameter
Larger diameter flexible pipelines require knowledge of the soil properties along the route of the pipeline and at the intended
depth of the pipeline for accurate structural design
GENERAL
LIMITATIONS
All pipelines require detailed site investigation and special designs for installations in contaminated land and sites where the
ground is subject to significant movement or subsidence
All pipes and fittings may be damaged by inappropriate cleaning practices and maintenance equipment
All pipeline systems have components that can be damaged by illegal discharges of trade waste
Plastic pipes are resistant to H2 S gas attack, impervious to groundwater and resistant to corrosion by almost all chemicals
found in sewage except some specific organic compounds
Thermoplastic pipes allow handling of much longer lengths and larger sizes than VC and GRP pipes, and are easier to cut
Vitrified clay pipes are resistant to H2 S gas attack and resistant to corrosion by almost all chemicals found in sewage
GENERAL
ADVANTAGES
Rubber ring jointed pipes are easily jointed and tolerate some joint deflection
All pipes can be used as slip liners inside microtunnelled/jacked encasing pipe
GRP, reinforced concrete and VC pipes can be supplied in designs for pipe jacking in microtunnelling installations
Rigid pipes have one or more pipe classes that have sufficient ring strength to not rely on side support for achieving structural
adequacy
Metallic pipes are easy to trace and, when fully welded, are impermeable to organic contaminants and gases
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WSA 022002-2.3
TABLE 10.2 (continued)

Informative
Flexible pipes may be susceptible to deflection after placement and compaction of embedment and fill
Plastic pipes may be susceptible to permeation and degradation by certain organic contaminants in soils
Plastic pipes and plastic coating or sleeving on metal pipes may be susceptible to degradation by certain organic contaminants
in soils
GENERAL
DISADVANTAGES
Plastic pipelines are sensitive to point loading

Rubber rings may be susceptible to degradation by certain organic contaminants in soils
Flexible pipes rely on support from embedment and adjacent native soil to achieve structural adequacy in buried installations
(except for some shallow installations without live loadings)
Non-black plastic pipes and fittings and plastic pipe coatings suffer UV degradation on prolonged exposure to direct sunlight
(generally 12 to 24 months depending on Australian locality)
PIPE
SYSTEM
TYPE
SPECIFIC ADVANTAGES
SPECIFIC DISADVANTAGES
NOT SUITABLE
SPECIAL APPLICATIONS
Fittings in riser structures prone

to failure if not appropriately
designed and supported
Fittings generally not available
off shelf
Can be solvent cement or
rubber ring jointed
ABS
Solid wall
Longer lengths
Solvent welding of large

diameter pipes requires
specialised training and
equipment
Beam strength may be
insufficient if pipe barrel is not
offered continuous support (load
dependent)
New product with limited
performance history
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Aggressive groundwater and

tidal zones
Above-ground
pipelines except
within conduits
Watercourse crossings as a
syphon
Crossing under railways or
major roadways within an
encasing pipe
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WSA 022002-2.3

Informative
PIPE
SYSTEM
TYPE
SPECIFIC
ADVANTAGES
NOT SUITABLE
Generally not used except

for special applications
requiring high strength
Above ground pipelines

except marine
environments, e.g.
aqueduct crossings, steep
slopes not allowing burial system designed not to
generate or receive H 2 S
Normal Portland cement not

resistant to H2 S gas attack
and sulphuric acid resulting
from H2 S
Ductile
Iron (DI)
Cement
mortar lined
High ring, beam and

shear strength
High ring stiffness
High alumina cement has

improved performance over
Portland cement
PE sleeving is required and
must be carefully applied and
repaired when damaged
especially by third-parties
Glass
reinforced
plastic
(GRP)
Centrifugally
cast
Available as micro
tunnelling and jacking
pipe
UV resistant (Special
product)
Fittings generally not available

off shelf
Poorly supportive native

soils
Damaged sections require

cutting out or repair using
couplings or clamps; in-situ
repair using epoxy patching
not advisable as methods not
proven
Ground subject to high

differential movement
Low beam and shear strength
Uncertainties in
geotechnical analysis to
determine if flexible pipe
structurally suitable
Where control of
construction practices is
not adequate to ensure
quality of embedment for
flexible pipes
Above ground where
vandalism possible
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Aggressive groundwater
and tidal zones
Trenchless technology
applications
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WSA 022002-2.3

Informative
PIPE
SYSTEM
TYPE
SPECIFIC ADVANTAGES
Can easily be curved to

eliminate need for bends
Suitable for directional
drilling, e.g. water course
crossings for syphons
Polyethylene
(PE)
Solid
wall
PE 80B
Available joint welding

provides higher confidence
in achieving long-term
leak-free system
Available in long coiled
lengths for fewer joints
Resistant to failure from
differential settlement or
pipe longitudinal flexibility
accommodates large
differential ground
settlement
NOT SUITABLE
Fusion jointing requires skilled

installers and special equipment
Aggressive groundwater and

tidal zones
Black pipe limits detectability of

defects by CCTV inspection
Soils with differential

movement
Out-of-trench jointing may be

necessary
Currently available fittings do not
cover all the specific
configurations required of
reticulation sewers
Fusion repair is difficult to
successfully achieve due to high
cleanliness/dryness
requirements and heating
controls
Requires much thicker wall than
PVC-U solid wall pipe to achieve
equivalent stiffness
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Reticulation systems
except for special
applications
Poorly supportive
native soils
applications
Watercourse crossings as a
syphon

encasing pipe
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WSA 022002-2.3

Informative
PIPE
SYSTEM
TYPE
SPECIFIC ADVANTAGES
Comprehensive range of
fittings
NOT SUITABLE
Fittings in riser structures prone

to failure if not appropriately
designed and supported
Fully integrated MSs available

Solid wall
Can be solvent jointed
Beam strength may be

insufficient if pipe barrel is not
offered continuous support (load
dependent)
Longer lengths than VC

Aggressive groundwater
and tidal zones
As for solid wall PVC plus:

PVCU
Sandwich
construction

Lighter than solid wall PVC for
the same ring stiffness
New product with little

performance history

Fully integrated MSs available
Profiled wall
Lighter than solid wall PVC for

the same ring stiffness
Some specialised fittings not

available
Cannot be solvent cement
jointed
3 m lengths in sizes DN 225 and
DN 300 cf 6 m in PVC solid wall
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Above-ground
pipelines except
within conduits

encasing pipe
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WSA 022002-2.3

Informative
PIPE
SYSTEM
TYPE
SPECIFIC ADVANTAGES
NOT SUITABLE
Above-ground pipelines
applications
Reinforced
concrete
(RC)
High beam and ring crushing

strength
Thermoplastic lined
Available as micro tunnelling
and jacking pipe
Field welding of PVC liner at pipe

joints is required to ensure
integrity of liner for resistance to
H 2 S gas attack
Fittings not readily available
Retrospective installation of
fittings/ repair complicated
Where soils
containing acid
sulphates are
encountered or
aggressive
groundwater or tidal
zones are relevant,
the limits of AS 4058
apply
As an alternative to large
diameter flexible pipes where:
Native ground modulus
inadequate to provide
structural support
Inadequate geotechnical data
available
Inadequate control over
embedment placement and
compaction
Likely third party interference
to the pipe surround
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WSA 022002-2.3

Informative
PIPE
SYSTEM
TYPE
SPECIFIC ADVANTAGES
NOT SUITABLE
SPECIAL
APPLICATIONS
Not totally impervious to groundwater

Low shear strength
Comprehensive range of fittings
High ring strength
Embedment requirements less

stringent than for plastic pipes
Standard
Vitrified
clay
(VC)
Less imported embedment

required
Disturbance of pipe side

support does not substantially
impair structural performance
unlike flexible pipe
Available as micro tunnelling
and jacking pipe
Beam strength may be insufficient if

pipe barrel is not offered continuous
support (load dependent)
High protrusion of socket requires
more careful preparation of bedding
to prevent a pipe length just being
supported at the socket
No longitudinal pipe barrel flexibility
to accommodate any loss of pipe
bedding continuity
Even minor cracks can lead to
penetration and chokes by
aggressive root systems
In the vicinity of trees with

aggressive root systems
Fittings in riser structures more

prone to failure than thermoplastic
fittings
Short pipe lengths in

mine subsidence areas
Highly susceptible to root intrusion

through rubber ring joints, likely due
to pipe permeability causing damp
external surfaces
As for standard VC plus:

Calcined
Almost totally impervious to

groundwater
Lighter than standard VC
As for standard VC plus:
Glazed
Totally impervious to
groundwater
As for standard VC except:

Susceptibility to root intrusion
through rubber ring joints is
uncertain and requires further
investigation
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Aggressive
groundwater and tidal
zones
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TABLE 10.3
PRINCIPAL SEWERAGE PRESSURE PIPELINE SYSTEMS
Informative
PIPE
CONVENTIONAL
PIPE SIZES
DN
DI
Cement
mortar
lined
100,
225,
375,
600,
150, 200,
250, 300,
450, 500,
750
TYPICAL PIPE
CLASSES
Rubber ring
seal
Ductile iron cement

lined (DICL)
K9
Restrained
joints
DN 100-300
Fusion bonded
polymeric
encapsulated ductile
iron
Series 1 (Metric)
Pressure classes
100, 150, 200,

250, 300, 375, 450
PN 9, PN 12,
PN 15
Unplasticised
Oriented
Modified
Series 2DI
compatible
100, 150, 200,
250, 300, 375, 450
Cement
mortar
lined
Steel
PE
coated
and
lined
100 2500
Pressure classes
Classes available
to meet all design
requirements
SN5000
SN10000
Glass reinforced
plastic (GRP)
Flanged
Fusion bonded
polymer encapsulated
ductile iron
Rubber ring
seal
Pressure classes
Sleeved ductile iron

cement lined
Post-formed PVC-U
or PVC-M bends
PN 9, PN 12,
PN 16
Stiffness classes
300, 375, 450,

525, 600, 675,
750, 900, 1000,
1200
FITTINGS
Pipe wall
thickness class
K12 - flanged pipe
PVC
JOINTING
METHODS
Rubber ringseal DN 300

1600
Welded
Steel with same

coating and lining as
pipe
Flanged
Tape wrapped SCL
GRP couplings
with rubber lip
seal
Fusion bonded
polymeric
encapsulated ductile
iron
Mechanical
couplings
PN 10, PN 12.5,
PN 16
PE sleeved DICL
Fusion bonded
polyethylene coated
SCL
Tape wrapped SCL
Fabricated GRP to
match pipe class
Polyethylene
(PE)
(solid wall)
Pressure classes
Mechanical
PN 10, PN 12.5,
PN 16
Electrofusion
63, 110, 125, 160,

180, 225, 280,
315, 450, 630
Butt fusion
Compression fittings,
couplings for DN 63
Electrofusion fittings
DN 110 DN 450
PE plain end for butt
fusion and
electrofusion
Flanged fittings
Mechanical fittings
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TABLE 10.4
PRINCIPAL SEWERAGE PRESSURE PIPELINE SYSTEMS
PRECAUTIONS, LIMITATIONS ADVANTAGES AND DISADVANTAGES
All pipelines may be damaged, rendered structurally unsound or have inadequate joint performance due to inappropriate
installation practices
All pipes and fittings may be damaged prior to installation by inappropriate transport, storage and handling practices
All pipelines should be constructed by trained and certified pipelayers with a system of documentation for quality control of
installation in place
GENERAL
PRECAUTIONS
All pipelines can be adversely affected in both the short and long term by third party damage to the pipe or corrosion protection
system
All pipeline systems may be damaged by illegal discharges of trade waste
All pipes require verification of the internal diameter for hydraulic designthe nominal size does not necessarily represent
accurately the internal diameter
All large diameter (DN 450) pipelines require a geotechnical investigation of the soil properties along the route and at the
intended depth of the pipeline
A risk assessment may be needed before locating pipelines in some locations, e.g. freeways, highways and major roads
GENERAL
LIMITATIONS
All pipelines require detailed site investigation and special designs for installations in contaminated land and sites where the
ground is subject to significant movement or subsidence
Electrically continuous pipelines constructed adjacent to electricity transmission lines >66kV shall comply with AS/NZS 4853
Plastic pipes are resistant to H2 S gas attack, corrosion resistant, relatively lightweight and easy to cut
GENERAL
ADVANTAGES
Metal pipes are easy to trace, do not require fatigue analysis and, when fully welded, are impermeable to organic contaminants
and gases
Rubber ring jointed pipes are easily jointed and tolerate some joint deflection
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WSA 022002-2.3

Informative
Plastic pipes may be susceptible to permeation by certain organic contaminants

Plastic pipes and plastic coating or sleeving on metal pipes may be susceptible to degradation by certain organic contaminants
Plastic pipelines require a detectable tracer tape for ease of location, although when installed with ductile iron fittings limited
traceability may be achieved
Plastic pipelines require de-rating at elevated temperatures and may require de-rating in certain surge and fatigue situations
GENERAL
DISADVANTAGES
Plastic pipelines are sensitive to point loading

Rubber ring jointed pipes may permit permeation through the joints in ground contaminated with organic compounds
Flexible pipes rely on support from embedment and adjacent native soil to achieve structural adequacy in buried installations
(except for some shallow installations without live loadings)
Metal pipes are susceptible to corrosion if their internal or external or both corrosion protection systems are damaged or fail
Non-black plastic pipes and fittings and plastic pipe coatings and sleeving suffer UV degradation on prolonged exposure to
direct sunlight (generally 12 to 24 months depending on Australian locality)
PIPE
SYSTEM
TYPE
SPECIFIC ADVANTAGES
Fatigue analysis not normally
required
High mechanical strength and
toughness
Ductile
iron (DI)
Cement
mortar lined
(DICL)
Ease of jointing
UV resistant/vandal proof
impact resistant
Well-established methods of
repair
Restrained joint systems
available
SPECIFIC
DISADVANTAGES
Standard Portland cement
mortars not resistant to H2 S
gas attack at any high points
or discharge points in the
main. High alumina cement
has improved resistance
PE sleeving is required and
must be carefully applied
and repaired when
damaged, especially by
third-parties
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NOT SUITABLE
State/Territory roads and main
thoroughfares
Railway crossings to AS 4799
Anaerobic
conditions or tidal
zones
In poor ground conditions where
high risk of subsidence
Non-tidal creek and culvert
crossings
Aqueducts and non-tidal bridge
crossings
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WSA 022002-2.3

Informative
PIPE
SYSTEM
TYPE
SPECIFIC ADVANTAGES
Alternative installation
techniques possible e.g. sliplining
UV resistant (Special product)
GRP
Centrifugally
cast
Custom-made specially
configured GRP pressure
fittings can be manufactured
to order
Suitable for use without
additional corrosion protection
in areas where stray electrical
currents occur
SPECIFIC
DISADVANTAGES
Low impact resistance and
ease of damage of
thermoset resin makes GRP
susceptible to damage
during transportation and
installation, in above-ground
installations or when
damaged from nearby
excavation
NOT SUITABLE
Above ground
locations subject to
interference
Aggressive groundwater,
anaerobic conditions and tidal
zones
fittings/ repair complicated
Can easily be curved
PE
PE 80B and
PE 100
Alternative installation
techniques possible e.g. pipe
cracking and slip lining
Fusion jointing requires

skilled installers and special
equipment
Can be welded to form a

system that will resist end
load
Out-of-trench jointing may

be necessary
DN 125 available in coiled

lengths for fewer joints
fittings/repair complicated
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Above ground
locations subject to
interference
Butt welding in
trenches
anaerobic conditions and tidal
zones
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WSA 022002-2.3

Informative
PIPE
SYSTEM
TYPE
Unplasticised
SPECIFIC ADVANTAGES
Oriented
Better fatigue resistance than PVCU and PVC-M

Available in long lengths (up to
12 m)
Modified
Available in long lengths (up to

13.5 m)
Custom-made specially configured
steel pressure fittings can be
manufactured to order
Steel
Can be welded to form a system

that will resist end loads
UV resistant/vandal proof/impact
resistant
Alternative installation techniques
possible e.g. slip lining
Cathodic protection can be applied
to provide enhanced external
corrosion protection
PE lined and
coated
Use only DI fittings in pumped

mains to achieve full fatigue
resistance
12 m lengths should not be used
directly with DI fittings
Above ground
pipelines
anaerobic conditions and
tidal zones
Better fracture toughness than

PVC-U
High mechanical strength and
toughness
Cement mortar
lined (SCL)
and PE coated
NOT SUITABLE
Well established methods of repair

Better fracture toughness than
PVC-U
PVC
As for SCL plus:

Resistant to H2 S gas attack
Standard Portland cement

mortars not resistant to H2 S gas
attack at any high points or
discharge points in the main
High alumina cement has
improved resistance
Welded joints require skilled
installers and special equipment
Welded joints require
reinstatement of protection
systems on site
Special design required for
welded installations parallel and
adjacent to high voltage (>66 kV)
transmission lines
Cathodic protection requires
regular monitoring and
maintenance
As for SCL except for comment
on cement mortar linings
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State/Territory roads and

main thoroughfares
Railway crossings to
AS 4799
High-pressure mains
anaerobic conditions and
tidal zones
Creek and culvert crossings
Aqueducts and bridge
crossings
Large diameter pipelines
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WSA 022002-2.3
APPENDIX F
QUALITY ASSURANCE OF PRODUCTS
QUALITY ASSURANCE OPTIONS AND SELECTION
(Informative)
F1 GENERAL
The objective of product quality assurance is to reduce the likely consequences (and costs)
of non-conforming product; however, the cost of quality assurance should be balanced
against the tangible and other benefits arising from its adoption.
One or more of the following quality assurance options are stipulated in each purchase
specification referenced by this Code:
(a)
ISO 9000 management system certification.
(b)
Product certification (either Type 1, 3 or 5).
(c)
Second party verification.
(d)
Suppliers declaration of conformance.
This appendix provides information on applicability and limitations of the various quality
assurance options.
This Appendix does not address quality of installation or operation and maintenance,
upon which satisfactory performance of a conforming product depends.
F2 QUALITY ASSURANCE OPTIONS
Although ISO 9001 or ISO 9002 management system certification may demonstrate that
there is systematic management of a part or whole of a supplier organisation, the scope
(breadth) and focus (depth) of the certification audit may be very general, particularly
where the organisation manufactures complex products or a diverse range of products.
Furthermore, an ISO 9000 management system certification audit does not necessarily
assess the compliance of a product to its specification.
On completion of a successful audit, the manufacturer is issued with a certificate that
includes a capability statement i.e. a general statement of the business activities covered
by the certification. A manufacturer may not apply a certification mark directly to a product,
but may do so on packaging.
A product certification audit specifically focuses on the products conformance to its
specification. Three types of product certification are referenced in this Code Types 1, 3
and 5. Depending on the type of product certification specified, the certification audit may
not include auditing of the manufacturing process(es). However, as a minimum in all cases,
product certification requires a type test to verify conformance. Product certification may
address some of the inadequacies of a generic ISO 9000 management system
certifications failure to specifically assess product or material conformance to
specification.
On completion of a successful audit, the Certification Body (CB) may licence the
manufacturer to apply the CB's mark to the product as evidence of independent verification
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WSA 022002-2.3
of conformance. The product certification certificate issued by the CB states the actual
specification to which the product has been declared to conform.
ISO lists various types of product certification that are differentiated by the scope, depth
and frequency of auditing and/or testing. Types 1, 3 or 5 are nominated by purchase
specifications referenced by this Code i.e.:
(a)
Type 1Type testing only (initial and thereafter at design change).
(b)
Type 3Type testing followed by subsequent audit testing of factory samples.
(c)
Type 5Type testing and on-going assessment / audit of the manufacturers

process controls.
Information on and comparison of these types is given below.

In Type 1 certification, the CB type tests or verifies that a satisfactory type test of a sample
of the product has been made. Tests for verifying critical performance attributes should be
stipulated in the product specification. Certification expires when there is a design change
(including materials and/or manufacturing method). Type 1 product certification is the
simplest and most limited form of independent certification of product conformance. There
is no follow-up testing or auditing by the certification body. Manufacturing quality control is
not considered.
The type test gives evidence only about a particular item made at a particular moment
in time. Alone, it gives no assurance that future items will be equivalent. Type testing
may verify a design and its capability to perform, subject to future items being
manufactured in an identical manner. Where possible, type testing should be
conducted by a NATA-accredited laboratory and reported on NATA-endorsed reports.
Type 3 is an extension of Type 1. There is periodic follow-up action by the certification
body to check, by audit testing of factory samples, that subsequent production conforms to
specification. In this Code, the frequency of audit testing is defined in the product purchase
specifications. Re-certification is required if there is a product design change.
Type 5 product certification is the most rigorous third party verification of a products
compliance with the specification to which it is manufactured. To achieve this level of
product certification, a manufacturer must have a suitable quality management system in
place and demonstrate to the satisfaction of the certification body that manufacturing
process controls, inspections and tests verify conformance to all significant aspects of the
product specification. Type testing, periodic testing of samples from the factory and
periodic auditing of factory quality control by the certification body is mandated. The CB
may require the manufacturer to have a full or part ISO 9000 management system.
Typically, Type 5 requires the CB to verify statistical manufacturing control or conduct
batch release testing.
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142

Third party certification does not permit a manufacturer or supplier to abrogate its
obligations.
According to the International Organisation for Standardisation:
An assurance given by the seller to the buyer is the oldest and simplest form of the
general practice of certifying that a product is in accord with a specification or contract
[Reference: Certification Principles and Practice, published by International Organisation
for Standardisation (ISO), 1980].
Under the Trade Practices Act, a manufacturers promotion, or response to a purchasers
enquiry, must not give false or misleading information.
A suppliers declaration should state that the supplier has taken reasonable steps to
ensure that the product or material complies with the specification quoted in the order;
otherwise variations must be documented and provided to the purchaser. The supplier
may be the manufacturer or the retailer of the product, depending on the distribution chain
and purchase transaction.
Second party verification of product, manufacturing process(es) and/or personnel
qualification involves the purchaser, or its agent, auditing the suppliers manufacturing
operations or inspecting finished product. This is generally in the form of an ISO 9000
management system audit or similar audit process. For complex products, a hold point in
manufacture may be specified whereby the purchaser audits or inspects the adequacy of
the manufacturing status prior to authorising continuation.
F3 FACTORS INFLUENCING SELECTION OF QUALITY ASSURANCE OPTIONS
In determining the default quality assurance requirement for a specific product, the
following issues are relevant:
(a)
Likelihood of manufacturing process causing a product non-conformance.
(b)
Likelihood of failure of the pipeline system from a product non-conformance.
(c)
Consequences of product failure.
(d)
The product specification.
(e)
Project magnitude / management.
(f)
Innovation
RISK = CONSEQUENCE OF FAILURE x LIKELIHOOD OF FAILURE
F3.2 Likelihood of manufacturing non-conformance

Variability of product quality and the reliability of quality assurance options are influenced
by the means of production.
Where the volume of production is high, sampling plans to AS 1199 or AS 2490 may be
used. Statistical sampling may not be applicable to low volume production processes or
jobbing fabrications, in which case focus on process and /or personnel qualification,
together with type testing, may be appropriate.
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WSA 022002-2.3
F3.3 Likelihood of failure of pipeline system from a product non-conformance

The likelihood of failure of a pipeline system from a product non-conformance depends on
the nature of the non-conformance. A non-conformance of a pipe to a specified internal
diameter would have little likelihood of causing to failure of a pipeline system. A nonconformance to a strength or stiffness requirement of a pipe could cause failure with low to
high consequence depending on how close the particular loading was to the failure limit for
the pipe / support selection i.e. standard stiffness small diameter PVC would have excess
loading capacity for most installations. A non-conformance to a specified external diameter
could affect joint sealing and may have a moderate to high likelihood of causing failure.
F3.4 Consequences of failure
A higher level of assurance of product compliance is required where the expected
detrimental consequences of failure resulting from any non-conformance are high. The
objective of quality assurance is to reduce the likelihood of non-conformance and
subsequent failure due to product design and/or manufacturing deficiency.
F3.5 Product specification
The product specification must be written such that it clearly specifies essential
performance requirements, attributes and test methods. These must be specified in a
manner that can be measured and objectively verified by the manufacturer and certification
body.
F3.6 Project magnitude / management
For contractual and other reasons, a major or special project may require specific quality
assurance provisions in lieu of the default quality assurance options stipulated in this
Codes product purchase specifications.
F3.7 Innovative products
This Code does not nominate specifications for innovative products, even though they may
have existing certification to a national or industry standard. For products undergoing trial
evaluations, a Water Agency may be prepared to accept or manage a (temporary) higher
level of risk.
Each agency should be responsible for stating its own quality assurance requirements
for innovative products.
F4 SELECTING THE QUALITY ASSURANCE OPTION
Selection of the appropriate quality assurance option for products is made after
considering the factors outlined above.
All types of product certification require that the product specification unambiguously and
objectively define product attributes and performance measures.
The principal factors applying in selection of quality assurance options in accordance with
this Code are:
(a)
Likelihood of non-conformances from the manufacturing process; and
(b)
Consequence and likelihood of failure of the pipeline system.
An outline of the applicability of various options is given in Clause F4.2.
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F4.2.1 General
Product certification is the preferred quality assurance option since the focus of the CB is
on directly verifying conformance of a particular product to its specification. In addition,
application of the CBs mark onto the product is objective evidence of the manufacturers
declaration of conformance.
F4.2.2 Type 1
Type 1 product certification should be nominated where:
(a)
the likelihood of the manufacturing process causing a non-conformance is low, e.g.

fully automated manufacturing and control, and manufacturing quantity is small;
and/or
(b)
the consequences of failure are low; and/or
(c)
the likelihood of failure is low.
Examples of products for which Type 1 product certification is applicable are nondetectable marking tapes and maintenance hole covers in non-trafficable areas.
For a product normally used in situations where failure would result in moderate
consequences of failure or where the likelihood of failure is moderate, Type 1 may be
specified in conjunction with an ISO 9000 quality management system certification if
Type 3 is not practicable.
F4.2.3 Type 3
(a)
the likelihood of manufacturing processes causing a non-conformance is moderate to

high and statistical sampling plans are not practicable e.g. a minor degree of manual
input to manufacturing; and/or
(b)
the consequences of failure are moderate; and/or
(c)
the likelihood of failure is moderate.
Examples of products for which Type 3 product certification is applicable are valve
chambers and maintenance hole covers in trafficable areas.
The frequency of CB surveillance audits should be increased to match an increase in the
likelihood of manufacturing non-conformances or increased risk of failure. Type 3 may be
specified in conjunction with an ISO 9000 quality management system certification if
Type 5 is not practicable.
F4.2.4 Type 5
(a)
the likelihood of manufacturing processes causing non-conformance on a large scale

and with consistent repetition is high, i.e. mass produced product; and /or
(b)
the consequences of failure are high; and/or
(c)
the likelihood of failure is high.
Examples of products for which Type 5 product certification is applicable are certain flow
control valves and buried pipes and fittings (excepting special low volume products).
For pipes made by batch processes or complex or speciality products, Types 1 or 3 plus
ISO 9000 quality management system certification may alternatively be specified.
Type 5 is specified where the risk of failure is high. It is commonly adopted for massproduced, critical products such as pipes, fittings and valves. However, it may not be
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WSA 022002-2.3
practicable for batch processes or complex or speciality products; for these, Types 1 or 3
plus ISO 9000 quality management system certification may be more appropriate.
ISO 9000 quality management system certification is generally nominated where the
expected consequence and likelihood of non-conformance is moderate or, for high risk
products, where product certification is not practicable. This is typically where there may
be many design changes (e.g. concrete) or for low volume, speciality products (e.g.
fabricated GRP fittings) or where the specification does not adequately specify objective
performance criteria.
Where this Code mandates an ISO 9000 quality management system certification as a
means of assuring product quality, the scope of the certification is required to be focused
and relevant to the product. Typically this requires the certificate issued by the CB to
specifically state the product type or process by which the product is produced (e.g.
manufacture and supply of concrete, to AS 1379.)
An ISO 9000 management system certification generally does not reference a product
standard or specification; however, for the above example, reference to AS 1379 in the
scope is appropriate since AS 1379 is process oriented.
Given the process focus of the 2000 edition of ISO 9000, there is potential to improve
the relevance of a generic ISO 9000 management system to the certification to
products.
A suppliers declaration of conformance should be required for all products.
Purchasers are expected to seek the suppliers declaration that product supplied against a
purchase order complies with the nominated specification.
A salient objective of third party (CBs) system or product certification is to minimise the
intervention of second parties (purchasers) in the suppliers production operations. Second
party auditing at the suppliers works may, however, be appropriate for low volume
fabricated items and may be used in conjunction with ISO 9000 management system
certification. This option may be an overriding option for the purchaser should product
quality problems be identified during the supply. The Water Agency or Designer may
determine the need for second party verification and specify this in the project contract
documentation.
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WSA 022002-2.3
146
NOTES
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Part 2: Products and Materials

APPENDIX F QUALITY ASSURANCE OF PRODUCTS AND MATERIALS

10 PRODUCTS AND MATERIALS OVERVIEW

nominate default product standards; and

provide default purchase specifications for products.

Nominating variations to the default purchase specifications and quality assurance

WSAA purchase specifications are listed on the WSAA website.

10.6 SELECTION GUIDE FOR PIPELINE SYSTEMS

150, 225, 300,

Rubber ring seal

100, 150, 225,

300, 375, 450,

Rubber ring seal

MHs, saddles for

PVC bends, junctions,

Rubber ring seal

PE plain end for butt

Stiffness and equivalent

Rubber ring seal

Pipe wall thickness

Rubber ring seal

Ductile iron cement

TABLE 10.2 (continued)

Plastic pipelines are sensitive to point loading

Fittings in riser structures prone

Solvent welding of large

Aggressive groundwater and

TABLE 10.2 (continued)

Generally not used except

Above ground pipelines

Normal Portland cement not

High ring, beam and

High alumina cement has

Fittings generally not available

Poorly supportive native

Damaged sections require

Ground subject to high

Low beam and shear strength

TABLE 10.2 (continued)

Can easily be curved to

Available joint welding

Fusion jointing requires skilled

Aggressive groundwater and

Black pipe limits detectability of

Soils with differential

Out-of-trench jointing may be

Crossing under railways or

TABLE 10.2 (continued)

Fittings in riser structures prone

Fully integrated MSs available

Beam strength may be

Longer lengths than VC

As for solid wall PVC plus:

As for solid wall PVC plus:

New product with little

Longer lengths than VC

Lighter than solid wall PVC for

Longer lengths than VC

Some specialised fittings not

Crossing under railways or

TABLE 10.2 (continued)

High beam and ring crushing