SPECIFICATION FOR DUCTILE IRON

PIPES, FITTINGS AND ACCESSORIES

4
3
2
1
0
rev.

16.06.2013
05.06.2008
12.03.2008
08.06.2004
02-02-2002

Included EN 545 : 2010

Harmonizing with QCP
EN 545, QCP and seismic impact considered
Review committee decision incorporated
Approved Issue

date

Description/issued for
prepared
authorised
client:
ADWEA
project:
STANDARD SPECIFICATIONS FOR WATER WORKS
title:
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project phase:
tender:

project:

document: W-P-SS-001

SKN
QA/QC
QA/QC

rev: 4

AMD

sheet: 1

of: 23

Table of Contents

page

1.

SCOPE OF SPECIFICATIONS ............................................................. 4

2.

APPLICABLE STANDARDS AND CODES .......................................... 4

3.

D.I. MATERIAL CHARACTERISTICS ................................................... 6

4.

D.I. PIPES .............................................................................................. 6

5.

D.I. FITTINGS ........................................................................................ 9

6.

JOINTS .................................................................................................. 9
6.1
Flexible Joints ......................................................................... 9
6.2
Flanged Joints ........................................................................ 10
6.3
Restrained Joints ................................................................... 10

7.

INTERNALPROTECTION TO D.I. PIPES AND FITTINGS ................. 11

7.1
General ................................................................................. 11
7.2
Surface Preparation ................................................................ 11
7.3
Cement.................................................................................... 11
7.4
Aggregates ............................................................................. 12
7.5
Additives ................................................................................. 12
7.6
Water....................................................................................... 12
7.7
Mortar ...................................................................................... 12
7.8
Method of Lining ...................................................................... 13
7.9
Curing...................................................................................... 13
7.10
Repair of Defective or Damaged Areas of Lining .................... 13
7.11
Thickness of the Lining........................................................... 13
7.12
Mechanical Properties ............................................................. 14
7.13
Quality of the Lining, Tests and Records................................. 14

8.

EXTERNAL COATING TO D.I. PIPES AND FITTINGS ...................... 15

8.1
General ................................................................................... 15
8.2
Metallic Zinc with Bituminous Coating to D.I. Pipes................. 15
8.3
Zinc Rich Paint with Bituminous Coating to D.I. Fittings .......... 16
8.4
Polyurethane Coating ............................................................. 16
8.5
Fusion Bonded Epoxy Coating ............................................... 20

9.

FLANGE ADAPTORS ......................................................................... 21

10.

STEPPED COUPLINGS ...................................................................... 21

11.

DISMANTLING JOINTS ...................................................................... 21

12.

SPLIT TEES FOR UNDER PRESSURE CONNECTIONS .................. 21

13.

PUDDLE FLANGES OR SEALING FLANGES ................................... 22

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 2

of: 23

14.

THRUST/ANCHOR FLANGES ............................................................ 22

15.

POLYETHYLENE SLEEVES............................................................... 22

16.

VENDOR DOCUMENTATION ............................................................. 23

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 3

of: 23

1.

SCOPE OF SPECIFICATIONS
This specification covers the general requirements for Ductile Iron (D.I.) pipes, fittings and
accessories including material specifications, internal lining, external coating, joints,
polyethylene sleeves etc. This specification sets the minimum acceptable requirements. In
case of difference between this specification and the specified international standards then
the most stringent requirements shall prevail

2.

APPLICABLE STANDARDS AND CODES

D.I. pipes, fittings and accessories including coating and polyethylene sleeve shall comply
with the latest issue of the following standards and other relevant standards noted elsewhere
in this specification:
ISO 62

Plastic Determination of water absorption

ISO 527

Plastics-Determination of tensile properties.

ISO 887

Plain washers for metric bolts screws and nuts.

ISO 974

Plastics-Determination of the brittleness temperature by impact.

ISO 2230

Vulcanised rubber-guide to storage.

ISO 2531/EN 545

Ductile iron pipes, fittings, accessories and their joints for water or
gas applications.

ISO 3506

Corrosion - resistant stainless steel fasteners.

ISO 4014

Hexagon head bolts Product grades A and B.

ISO 4032

Hexagon nuts, style 1 Product grades A and B.

ISO 4179

Ductile iron pipes and fittings for pressure and non-pressure pipeline
Centrifugal cement mortar lining

ISO 4587

Adhesives Determination of tensile lap-shear strength of rigid-torigid bonded assemblies.

ISO 4633

Rubber seals Joint rings for water supply, drainage and sewerage
pipeline Specification for materials.

ISO 16134

Earthquake and subsidence resistant design of ductile Iron pipes

ISO 6506-1

Metallic materials Hardness testing Brinell test Part 1: Test

method.

ISO 6708

Pipeworks components Definition and selection of DN (nominal

size).

ISO 7005-2

Metallic flanges Part 2: Cast iron flanges.

ISO 7268

Pipe components Definition of nominal pressure.

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 4

of: 23

ISO 7483

Dimensions of gaskets for use with flanges to ISO 7005.

ISO 8179-1

Ductile iron pipes External coating Part 1: Metallic zinc with

finishing layer.

ISO 8179-2

Ductile iron pipes External coating Part 2: Zinc rich paint with
finishing layer.

ISO 8180

Ductile iron pipes Polyethylene sleeving for site application.

ISO 8501-1

Preparation of Steel Substrates.

ISO 9001:2000

Quality Management System

ISO 10804

Restrained joint systems for ductile iron pipelines Part 1: Design

rules and type testing.

ISO 8503-1

Preparation of steel substrates before application of paints and

related products.

EN 1092-2

Circular flanges for pipes, valves, fittings and accessories, PN

designated Part 2: Cast iron flanges.

EN 14901

Epoxy coating of ductile iron pipes, fitting and accessories

EN 15189

External Polyurethane coating for DI Pipes & Fittings.

EN 197-1

Cement composition specifications and conformity criteria for

common cement

BS 2782

Methods of testing. Plastic. introduction

BS 3416

Specification for bitumen - based coatings for cold application

suitable for use in contact with potable water

BSEN 10025

Hot rolled products of non-alloy structural steels

DIN 30671

Thermosetting plastics coatings for buried steel pipes

DIN 30672

Coatings of corrosion protection tapes and heat Shrinkable material.

DIN 4226

Aggregates for concrete and motor.

ASTM E 28

Standard test methods for softening point of resins derived from

naval stores by ring-and-ball apparatus

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 5

of: 23

3.

D.I. MATERIAL CHARACTERISTICS

Ductile iron pipes, fittings and accessories shall meet the following requirements :
Minimum tensile
strength, Rm

Minimum elongation after fracture, A

MPa

Type of casting

DN 40 to DN 2 000

DN 40 to DN 1 000

DN 1 100 to DN 2000

Pipe centrifugally cast

420

10

Pipe not centrifugally cast,

fittings and accessories

420

By agreement between contractor and ADWEA, the 0,2% proof stress (Rp0,2) may be
measured. It shall be not less than:
- 270 MPa when A > 12 % for DN 40 to DN 1 000 or A > 10% for DN > 1 000:
-

4.

300 MPa in other cases.

D.I. PIPES
All D.I. pipes supplied shall be truly circular, of uniform thickness and supplied in the
longest practicable length so as to minimise the number of joints, as per EN 545 (table 3).
Unless otherwise specified in the drawings or in the Particular Specification all pipes, joints
and fittings shall be suitable for the maximum pressure under which they will operate
(normal service pressure + surge pressure or the maximum site test pressure whichever is
greater) and shall sustain without damage or substantial leakage the specified site
hydrostatic test pressure.
Nominal iron wall thickness of pipes & fittings shall be according to either EN 545 :2006 or
EN 545 : 2010. DI pipes & fittings manufacturer shall provide certificates from recognized
international agencies to confirm process compliance to relevant international standards (ie.
EN 545 : 2006 or EN 545 : 2010)
In case of EN 545 : 2006
The nominal iron wall thickness of pipes shall be in accordance with class K9 of EN 545 :
2006 and calculated as a function of the nominal size, DN, by the K class formula, with a
minimum of 6 mm for pipes and 7 mm for fittings:
e

K(0.5 + 0.001 DN)

Where :

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 6

of: 23

'' e '' is the nominal wall thickness, in millimetres;

DN is the nominal size in millimetres;
K is a coefficient used for thickness class designation. It is selected form a series of whole
numbers.8, 9, 10, 11, 12
or defined according to EN 545 : 2006, 4. 2.1. 3 for class 40 pipes of DN 40 to DN400
All pipes shall be subject to Inspection during manufacturing.
The name of manufacturer, standard, nominal diameter (DN), the PN rating when
applicable, type of socket, class and year of manufacturing shall be cast or cold stamped
inside the socket. The CONTRACT number shall be painted on the pipe.
Pipes shall be hydrostatically pressure tested for leak tightness and certified at the
manufacturer's plant prior to coating or lining for at least 10 seconds at the following test
pressures (bar):

Pipe centrifugally cast

DN

Pipes not centrifugally cast and

fittings a

Class 40

K<9

K>9

All thickness classes

40 to 300

40

0,5 (K+1)

50

25b

350 to 600

40

0,5K

40

16

700 t0 1 000

0,5 (K-1)

32

10

1 1000 to 2 000

0,5(K-1)

25

10

The works hydrostatic test pressure is less for fittings than for pipes because the
shape of the fittings makes it difficult to provide sufficient restraint to high internal
pressure during the test.
b

16 bar for pipes and fittings with PN 10 flanges.

The maximum DN for class 40 pipes is DN 400.

In case of EN 545 : 2010

The minimum wall thickness of pipes, emin, shall follow the thickness of the preferred
pressure class and shall not be less than 3.0mm The iron thickness for pipes shall be
determined using the following equation
emin, = PFAxSFxDE/ (20Rm +(PFA x SF))
Where

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 7

of: 23

Emin

- is the minimum pipe wall thickness in millimetre

PFA

- is the allowable operating pressure, in bar

SF

- is the safety factor for PFA (= 3)

DE

- is the nominal pipe external diameter, in millimetre.

Rm

- Is the minimum tensile strength of ductile iron,

DN

- Nominal pipe diameter

For pipes centrifugally cast, the minimum wall thickness e min, shall not be less tham 3.0mm.
The nominal wall thickness enom, is equal to the emin + (1.3 + 0.001DN)
For centrifugally cast pipes, nominal pipe wall thickness for preferred ductile iron pressure
classes shall be according to EN 545 2010 Table 16
All pipes shall be subject to Inspection during manufacturing.
The name of manufacturer, nominal diameter (DN), PN rating when applicable, and year of
manufacturing shall be cast or cold stamped inside the socket. The CONTRACT number,
reference to International Standard, C pressure class of pipe shall be painted on the pipe.
Pipes shall be hydrostatically pressure tested for leak tightness and certified at the
manufacturer's plant prior to coating or lining for at least 10 seconds at test pressures (bar).
For centrifugally cast pipes the internal hydrostatic pressure shall be raised until it reaches
the works hydrostatic test pressure equal to the pressure class and limit to the pressure of
preferred classes. For fittings and non centrifugally cast pipes test pressure shall be:
Pipes not centrifugally cast and fittings
DN
All thickness classes
40 to 300

25

350 to 600

16

700 t0 2600

10

Unless otherwise stated in the Particular Specification all D.I. pipes supplied shall be of
socket and spigot end.
It shall be the CONTRACTOR's sole responsibility to order a percentage (minimum 2%) of
the total length per diameter of pipes as calibrated pipes, for the purpose of cutting etc.
These pipes shall be clearly marked and shall not be used for normal pipe laying unless it
becomes clear that they are not required for the purpose of cutting any more. The
percentage to be ordered shall give due regard to any changes in route which may occur
during the course of the work for whatever reason.
Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 8

of: 23

Contractor shall consider in his design the seismic zone as defined by the municipality.

5.

D.I. FITTINGS
All D.I. fittings supplied shall be truly circular of uniform thickness according to ISO 2531
and EN 545.
All fittings shall be subject to Inspection during manufacturing.
Dimensions and nominal iron wall thickness of fittings shall be in accordance with the ISO
2531/EN 545.
For fittings the thickness '' e ''is the nominal thickness corresponding to the main part of the
body. The actual thickness at any particular point shall be increased where necessary to
meet localised high stresses depending on the shape of the casting (e.g. at internal radius
of bends, at the branch body junction of tees, etc).
Name of manufacturer, nominal diameter (DN), the PN rating, and year of manufacturing
shall be cast or cold stamped inside the socket or on the barrel of the fittings. The contract
number, clients name, reference to EN 545 and class shall be painted on the fitting.
Fittings shall be pressure tested for leak tightness and certified at the manufacturer's plant
prior to coating or lining. The pressure test shall be carried out for at least 10 seconds either
with air at a pressure of 1 bar or with water at the pressure indicated below:

25 bar for fittings DN 300 and smaller (for fittings with PN 10 flanges test pressure shall
be 16 bar)

16 bar for fittings DN 350 through DN 600

10 bar for fittings DN 700 and larger

6.

JOINTS

6.1

FLEXIBLE JOINTS
Flexible joints shall be of spigot and socket "push-on" type suitable for angular deflection in
any direction and capable of axial movement to compensate for thermal expansion or
contraction and ground movement. All flexible joints for D.I. pipes and fittings shall be
designed in compliance with ISO 2531/EN 545. Test certificate to be provided.
Joints may permit angular deflection to accommodate ground movements and to negotiate
large radius bends. All joints shall be designed to be fully flexible. Consequently, the
allowable angular deflection declared by the manufacturer shall not be less than

3.5 for DN 40 to DN 300

2.5 for DN 350 to DN 600

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 9

of: 23

1.5 for DN 700 to DN 2000

Rubber ring joints shall be of a type that will not deteriorate under local conditions either
during storage or during operation. The rubber gasket shall be of EPDM elastomer or
equivalent in accordance with ISO 4633 suitable for drinking water supply.
Where mechanical type joints are specified, proposed and approved they shall be supplied
complete with approved gaskets, glands, hot dipped galvanized or cadmium plated bolts or
ductile iron bolts, nuts and all other necessary accessories. Where retainer glands are
specified they shall be supplied with bolts and/or other necessary accessories.
6.2

FLANGED JOINTS
Flange ended pipes and fittings shall only be used when connecting to valves or other
special fittings as approved by ADWEA/ENGINEER.
The flanges shall be raised faced and integrally cast or welded on. Screwed on flanges or
glued on flanges are not acceptable. Rotatable flanges may be used for pipes and fittings
up to DN 600.
The dimensions and drilling of the flanges shall be to ISO 7005-2 or EN 1092-2. However in
case connections have to be made to other systems based on other standards contractor is
responsible to verify. The pressure rating of the flanges shall be as given in the Data Sheet
or Particular Specification. Flanged joints shall be supplied complete with gaskets, hot
dipped galvanized or cadmium plated nuts, bolts and washers.
Rubber gaskets shall be EPDM elastomer or equivalent approved in accordance with ISO
4633 suitable for drinking water supply. The gasket shall be minimum 3 mm thick and shall
be reinforced as per pipe system requirement. For piping systems with pressure rating of
PN 16 or above gaskets shall be steel reinforced. The dimensions of the flange gaskets
shall be to ISO 7483.
The nuts, bolts, washers shall be of steel having minimum tensile strength of 400 N/mm2
hot dipped galvanised or cadmium plated. Nuts and bolts shall be suitable for the pressure
rating specified in the Particular Specification. Nuts and bolts shall be to ISO 4014 and
4032 and washers to ISO 887.

6.3

RESTRAINED JOINTS
D.I. pipes and fittings with restrained joints shall be utilised where pipelines have to cross
roads through existing ducts/ culverts/ NDRC or in areas with restricted accessibility where
the use of concrete thrust blocks/ line anchor is prohibited, or as directed by
ADWEA/ENGINEER. The CONTRACTOR shall submit with his bid full details of the type of
restrained joints he proposes to use.
Whenever in the course of work the CONTRACTOR intends to utilise restrained joints he
shall obtain prior approval from ADWEA/ENGINEER.

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 10

of: 23

Calculation of the number of pipe lengths with restrained joints required shall follow the
manufacturer's recommendation and shall be subject to ADWEA/ENGINEER approval.
Restrained joints shall be designed to resist the axial thrust forces but maintaining flexibility
and angular deflection. Restrained joints shall be designed in accordance with ISO 10804-1
and EN 545. The joint shall be capable of withstanding the greater of the test pressure or
the service pressure + the surge pressure.
The type of restrained joint shall be subject to ADWEA/ENGINEER approval.
The thrust resisting mechanism shall be separated from the sealing action of the gasket and
shall not be in contact with potable water in the pipeline.
7.

INTERNALPROTECTION TO D.I. PIPES AND FITTINGS

7.1

GENERAL
Unless otherwise specified in the Data Sheet or Particular Specification all D.I. pipes shall
be internally lined with cement mortar in accordance with the following specification and
shall be certified as suitable for use with potable water by an internationally accepted
organisation.
For DI Fittings, cement mortar lining or fusion bonded epoxy shall be acceptable except for
fittings inside chamber and pump house which shall be coated with non toxic fusion bonded
epoxy..
The cement mortar lining for D.I. pipes and fittings shall be in accordance with the
requirement of EN 545.
The internal surface of the socket bell of all zinc/bitumen coated D.I. pipes and fittings shall
be painted with zinc rich paint (150g/m), with a non toxic epoxy of bitumen finishing layer of
100 microns minimum or non-toxic solvent-free two part epoxy coating applied to a
minimum dry film thickness (DFT) of 300 microns or equivalent corrosion protection system
to be approved by ADWEA/ENGINEER. The thickness of the coating may be reduced only
at the gasket locating ring to conform to manufacturer's recommended tolerances.

7.2

SURFACE PREPARATION
Prior to cement lining application the inner surfaces of pipes and fittings shall be cleaned of
dirt, loose rust particles, grease, oil or any other material which could be detrimental to good
contact between the metal and the lining.

7.3

CEMENT
Cement to be used shall be of any cement type (OPC or SRC) complying with the
requirements of EN 197-1. The type of cement chosen by the CONTRACTOR shall be as
per manufacturer's fabrication standards process.

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 11

of: 23

7.4

AGGREGATES
Only clean, rounded or crushed natural mineral materials aggregates shall be used in
accordance with the requirement of the latest issue of ISO 4179 standards.
The sand used shall have a controlled granulometric distribution from fine to coarser
elements. The granulometric curve of the sand shall be appropriate to the lining thickness
and method of application.
The cleanliness of sand shall be evaluated in terms of organic impurities and clay bearing
substances. The test of organic impurities shall be carried out by a colorimetric method in
accordance with the standards in force in the producing country; the sand shall not produce
any coloration darker than that of the reference solution.
The determination of the content of clay-bearing substances in the sand (having dimensions
less than 63 microns to 90 microns depending on the country) shall be carried out in
accordance with the standards in force in the producing country; it shall not exceed 2% by
mass.

7.5

ADDITIVES
The use of cement additives is allowed, subject to ADWEA/ENGINEER approval, provided
that they do not adversely affect the quality of the lining, and that of the transported water.
Contractor shall declare the type of additive he is using if any.
Additives shall not contain any elements which impart potable change in colour, taste or
odour or present a health hazard. Certificates of non toxicity prepared and signed by
recognised, independent laboratories, shall be made available to ADWEA/ ENGINEER.

7.6

WATER
Water used for the mortar shall be of potable water quality, water provided by the local
authority / utility is acceptable and shall not contain elements which influence the hardening
of the lining or the quality of the water flowing through the finished pipes. Water used for the
mortar shall be deemed to comply with EN 545: 2010 clause 4.5.3.1 requirements.

7.7

MORTAR
Mortar for the lining shall be composed of cement, sand and water. The mortar shall be
well mixed and of proper consistency to produce a dense homogenous lining that will
adhere firmly to the DI pipe or fitting surface.
Weight of cement and sand shall be accurate to + 3%.
The mortar shall contain at least than one part of cement to 3.5 parts of sand by mass as
per ISO 4179.
Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 12

of: 23

7.8

METHOD OF LINING
Lining application and quality for finished surface shall be in accordance with ISO 4179.
All pipes shall be lined by a centrifugal process. The consistency of the mortar and the time
and speed of spinning the pipe shall be so adjusted to minimise the segregation of
aggregates from the cement.
Fittings shall be lined by a spray method.
In all cases a smooth finish of the lining shall be obtained, entirely free from cavities or
visible air bubbles, so that minimum thickness and optimum density are ensured at all
points.
The lining shall be uniform and extend from the spigot end up to the beginning of the socket
cavity on the other side. The socket shall be left free of mortar.
No seal coat shall be applied to the cement lining unless otherwise instructed and approved
by ADWEA/ENGINEER.

7.9

CURING
After application to pipes and fittings, the cement mortar shall be cured under controlled
conditions (minimum 48 hours at more than 15 deg.C and 75% relative humidity).
Alternative methods of curing are subject to approval of ADWEA/ENGINEER.

7.10

REPAIR OF DEFECTIVE OR DAMAGED AREAS OF LINING

7.11

Defective or damaged areas of lining may, at ADWEA's/ENGINEER's discretion, be

patched by cutting out the defective or damaged lining to the metal so that the edges of
the lining not removed are perpendicular or slightly undercut. The cut out area shall
then be repaired using the manufacturer approved method Water of potable quality,
with non toxic additive dispension of synthetic materials subject to
ADWEA's/ENGINEER's approval.

THICKNESS OF THE LINING

Thickness of the cement mortar lining shall be as follows:

Normal

80 600

5.0

4.5

3.5

700 1200

6.0

5.5

4.5

1400 2000

9.0

8.0

7.0

2200 2600

12.0

10.0

7.0

Client
Project:
Title:

project phase:

Lining Thickness (mm)

Minimum Mean
Minimum Value at
Value
One Point

DN (mm)

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 13

of: 23

N.B.:
7.12

The above figures differ from ISO 4179.

MECHANICAL PROPERTIES
The cement mortar lining shall have adequate resistance against compression and bending
action. Representative test pieces shall have the following minimum properties after 28
days.

7.13

Water Cement Ratio of Test

Piece

Compression Strength
2
N/mm

Bending Strength
2
N/mm

< 0.35

50

6.0

QUALITY OF THE LINING, TESTS AND RECORDS

The lining shall be free from voids, ridges or corrugations that reduce the thickness of the
lining to less than the specified minimum thickness.
Lining shall have a smooth surface. There shall be no cavities or entrapped (air bubbles),
similarly there shall be no evidence of differences between portions of lining.
Linings shall be placed so that there is no gap between the pipe barrel and the lining.
In some circumstances thicker linings may be required and these shall be stated in the
appropriate specification.
If a lining is damaged it may be repaired on site using a one to one cement/sand mortar
mix. (proportions by weight). Repairs shall cure for at least 72 hours.
Mortar lining may show evidence of cracking, crazing or debonding after delivery to site.
The following conditions may be accepted.
a)

Cracking - provided that the longitudinal length of a crack is not more than 600 mm,
width of crack not more than 0.8 mm, circumferential cracks are not more than 50% of
the circumference.

b)

Crazing - provided that individual cracks are less than the limits given in a), crazing
over an area not exceeding 25% of the lining area may be acceptable.

c)

Debonding - area of disbondment and radial displacement shall not exceed the values
given in EN 545.

The following tests and measurements shall be conducted, recorded and filed with
frequencies according to ISO 4179.

Determination of lining thickness.

Cross sectional sample.

Aggregates.

Bonding and compression strength.

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 14

of: 23

8.

EXTERNAL COATING TO D.I. PIPES AND FITTINGS

8.1

GENERAL
Depending on the existing local conditions the external coating of D.I pipes and fittings shall
be one of the following as given in the Data Sheets or Particular Specifications.
1.

Metallic zinc with bituminous coating layer. (Standard coating for pipes + fittings)

2.

Zinc rich paint with bituminous coating layer. (Standard coating for fittings)

3.

Polyurethane coatings. (Pipes in Subkha areas)

4.

Fusion bonded epoxy coating. (fittings)

Note : All Fittings/ Pipes inside Chambers and pump house should be Fusion bonded
epoxy coatings internally & externally.

A paint sheet to be provided giving the details of the painting system.

All coatings are subject to the prior approval of ADWEA/ENGINEER.
Where non-toxic coating is specified, certification shall be required from an internationally
recognised independent laboratory certifying that the material is safe for potable water
service. At the discretion of ADWEA/ENGINEER all special coatings on pipes and fittings
shall be subjected to thickness checks and for holiday testing in order to satisfy
ADWEA/ENGINEER that the coatings are within the specified limits and that no pin holes
are present.
The thickness of the coatings may be reduced only at the gasket locating ring to conform to
manufacturer's recommended fitting tolerance.
8.2

METALLIC ZINC WITH BITUMINOUS COATING TO D.I. PIPES

The system consists of a factory applied metallic zinc layer to ISO 8179-1 and a finishing
layer of black bituminous coating of tropical standard to BS 3416 with a minimum dry film
thickness (DFT) of 100 micron at any paint.
The zinc content shall be minimum 99.99% by mass and the mean mass of the zinc coating
2
shall not be less than 200 g/m with a local minimum of 180g/m applied on the bare metal
of the external surface of the pipe.
The external surface of the D.I. pipe spigot end at a minimum length of 250mm shall have
non-toxic bituminous paint applied to a minimum DFT of 100 microns.
Note:

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 15

of: 23

The internal surface of the socket end shall be painted with a layer of zinc rich paint 150
g/m2 (zinc content not less than 85%) plus a layer of non-toxic bituminous paint to a
minimum DFT of 100 microns and a mean average DFT of 120 microns.
8.3

ZINC RICH PAINT WITH BITUMINOUS COATING TO D.I. FITTINGS

The system consists of factory applied zinc rich paint layer to ISO 8179-2 and a finishing
layer of black bituminous coating of tropical standard to BS 3416 with a local minimum DFT
of 100 micron.
2

The mass of the zinc rich coating shall not be less than 150 g/m with a local minimum of
130 g/m and shall contain minimum 85% zinc in the dry film.
The external surface of the D.I. fitting spigot end at a minimum length of 250mm and the
internal surface of the socket end, which may have direct contact with potable water, shall
have a non-toxic bituminous paint applied to a minimum dry film thickness of 100 microns,
and a mean average DFT of 120 micron.
Note:
Contractor shall provide for paragraph 8.2 & 8.3 a table which correlates the thickness with
the mass of zinc.
8.4

POLYURETHANE COATING

8.4.1

GENERAL
This section covers the factory application of solvent free polyurethane coating to D.I. pipes
and fittings by airless, hot-spray techniques. . The surface of the D.I pipe shall be coated
with polyurethane in accordance with EN 15189, with an average thickness of 2000 microns
and a minimum thickness of 1500 microns. The external surface of the spigot end at a
minimum length of 250mm and the internal surface of the socket end which may have direct
contact with potable water shall have non-toxic solvent free two part epoxy coating applied
to a minimum dry film thickness of 300 microns in accordance with EN 14901 with the
exception of designated areas such as joint areas, edges, etc., with localised minimum
thickness of 100 microns is permissible as described in clause 3.13 of the European
Standard EN 14901:2006. The manufacturer shall provide a third party certificate of
conformity with the EN 15189 which shall cover the performance requirements (see 8.4.2)
and the inspection requirements (see 8.4.5)
8.4.2
Performance requirementThe manufacturer shall prove that the polyurethane
lining has been tested for the performance requirements as mentioned in EN 15189 and the
obtained results meet the requirements of the standard as detailed in the following table.
No

Parameter

Chemical resistance

Client
Project:
Title:

project phase:

Requirement
Less than 15% weight
increase after immersion.
Less than 2% weight loss
after drying.

Test Method
Immersion in deionised water
EN ISO 62 method 2

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 16

of: 23

Chemical resistance

Less than 10 % weight

increase after immersion
Less than 4 % weight loss
after drying

Impact strength

8 j/mm Polyurethanecoated pipe barrel 5 j/mm

for epoxy coated end
(see EN14901)

Immersion in diluted
Sulphuric acid 10% EN
ISO 62 method 2
Dropping weight
High voltage test

Indentation resistance

< 10 % at 10 MPa

Indentation test

Elongation at break

> 2,5 %

Tensile test

Specific coating
resistance in 0,1 M NaCl

> 10 m

Ratio of coating
resistance

0,8

Resistivity test towel

method or vessel method
Res.100 d/ res. 70d

Refer to EN 15189 for precise definition of the test methods

8.4.3

SURFACE PREPARATION
All slag shall be removed and all sharp edges shall be ground down. Prior to blasting, all oil,
grease, etc. shall be removed. All surfaces to be coated shall be blast cleaned to ISO
8501-1. Level SA 2.5.
The CONTRACTOR shall ensure that the type of abrasive used, its particle size and the
blasting pressure used are suitable for achieving the required profile. The compressed air
used in blasting shall be clean, dry and oil free.
After blast cleaning all dust shall be removed by vacuum or a clean, oil free, dry air blast.
The application of the coating shall follow with the least possible delay.
Any pipe not coated within 4 hours after blast cleaning shall be completely re-blasted before
coating.
The surface to be coated shall be maintained at a temperature of at least 5 C above the
dew point of the surrounding atmosphere at all times during the coating procedure.

8.4.4

APPLICATION
The polyurethane coating shall be applied using airless spray painting equipment strictly in
accordance with the paint manufacturer's recommendations.
The paint shall be applied in a continuous process to achieve a covering film free from
misses, tears, runs, sags, etc. and the minimum dry film thickness at any point as stated in
Table 1 above.
All painted area shall be thoroughly dried before being over-coated and be free of all loose
particles, dust, debris and atmospheric contamination.

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 17

of: 23

The external surface of the D.I. pipe spigot end at a minimum length of 250mm and the
internal surface of the socket end which may have direct contact with potable wall shall
have non-toxic solvent free two part epoxy coating applied to a minimum dry film thickness
of 300 microns.
8.4.5

INSPECTION
The pipe coating shall be completely free from porosity (holiday), voids, pinholes or other
defects. The following Routine test shall be performed by the manufacturer at his coating
application workshop with the frequencies defined in the following table and in accordance
with EN 15189
No

Parameter

Requirement

Surface
preparation

SA 2,5 of EN ISO 8501-1

Surface
roughness

Ra > 10 m

Appearance and
continuity

Test Method
Visual

100 %

min 1/shift

EN ISO 8503-1

Uniform and smooth

Minimum coating
thickness

Repairs

Non-porosity

No electrical break
through at required test
voltage

Hardness

> 70 Shore D

Adhesion

> 8 Mpa at 23 C

Frequenc
y

Visual

100 %

(x 2 ) > 1500 microns

5.2.2 Non destructive

instruments error 10 %

Manufacturers written

High voltage test

min.
1/shift
100 %

instructions
High voltage test at 10 kV

Each pipe
Hardness test

min.
1/shift

Punch separation method

acc. EN ISO 4624

1 per 1 000
pipes

The CONTRACTOR shall provide and operate an approved non porosity (holiday) detector
with a loud alarm operating at the voltage specified. Non porosity detection shall be carried
out over 100% of surface area of each pipe. The non porosity test shall be carried out in
accordance with EN 15189.
8.4.6

REPAIRS
In the event that problems are detected or repairs are needed, the CONTRACTOR shall
take immediate steps to correct the situation.
Scars, dents, damaged areas and holidays shall be cleaned by removing all rust, scale, dirt
or foreign materials or loose coating.

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 18

of: 23

Repairs either in the factory or subsequently on site are to be made by means of a repair
procedure approved by ADWEA/ENGINEER prior to commencement of work.
Any pipe subject to a coating repair procedure shall be fully re-examined in accordance with
above inspection requirements.
If cathodic protection is provided for the coated pipeline, coating at electrical connections
shall be repaired according to the approved repair procedure.
8.4.7

JOINT PROTECTION
All joints of polyurethane ductile iron coating coated pipes shall be protected by heatshrinkable pipe sleeves or collars. The heat-shrinkable sleeves or collars shall have a high
shrink ratio as well as high penetration resistant thick walled structure which together with
an internally coated adhesive mastic sealant shall ensure a reliable vacuum-tight anti
corrosion coating over the bare pipe joint and the polyurethane coated pipe ends.
The heat-shrinkable sleeve shall be manufactured from a radiation cross-linked, thermally
stabilized, UV-resistant modified polyolefin sheet material with an inner surface of a
controlled thickness visco-elastic sealant which shall be in accordance with the following
minimal requirements:
Heat-Shrinkable Sleeve Material

PROPERTY

TEST
METHOD

REQUIREMENT

TYPICAL
VALUE

Tensile strength

ISO 527

23C, CHS*
mm/min

50

17 MPa (min.)

24 Mpa

Ultimate elongation

ISO 527

23C, CHS*
mm/min

50

500% (min.)

750%

Impact brittleness

ISO 974

Below 40C

Pass

Thermal ageing

DIN 30672

100C, 100 days

Ultimate elongation

ISO 527

23, CHS*
mm/min

Water absorption

ISO 62

23C, 24 hrs.

0.1 % (max.)

0.05%

PROPERTY

TEST
METHOD

CONDITION

REQUIREMENT

TYPICAL
VALUE

Softening Point

ASTM E28

85C (min.)

92C

CONDITION

Followed by test for

50

-25% loss
elongation

of

4%

Sealant Material

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 19

of: 23

Peel strength to steel,

PE and epoxy

DIN 30672

23C, CHS* 100

mm/min

15 N/cm (min.)

25 N/cm

Peel strength to steel

DIN 30672

23C, CHS* 100

mm/min

12 N/cm (min.)

25 N/cm

23C,
1
mm
thickness, CHS*
50 mm/min

10 N/cm2 (min.)

15 N/cm2

After conditioning for 100 days at 50C

Shear strength

ISO 4587

* CHS = cross head speed

Dimensions

8.5

Backing thickness as supplied :

0.9 mm nominal

Sealant thickness as supplied :

1.5 mm nominal

Sleeve width as supplied

300, 450 or 600 mm nominal.

FUSION BONDED EPOXY COATING

The system consist of factory applied fusion bonded powder epoxy coating externally and
internally. The minimum dry film thickness of the coating shall be 300 microns.
The powder epoxy resin shall be applied by electrostatic spray and shall be non toxic
suitable for use in contact with drinking water. The powder material and method of
application shall be subject to ADWEA/ENGINEER approval.
The D.I. pipe or fitting shall be blast cleaned to SA 2.5 as per ISO 8501-1.
The temperature of the metal shall be adjusted to ensure complete polymerisation of the
powder material.
After coating application the coating shall be allowed to cure before being cooled with water
to permit handling and inspection.
The coating shall be free from blisters, pinholes, runs, sags or any other irregularities and
shall have uniform colour, gloss and thickness.
The coating shall be free from porosity (holidays). Every D.I. pipe or fitting shall be
inspected for non porosity over 100% of its coated surface. The non porosity (holiday)
detector shall be set at 2.2 kV with a rate of travel of the probe over the surface shall not
exceed 300 mm/s.
The minimum impact resistance of the coating shall fulfil the requirements of EN 14901,
7.2.4.
Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 20

of: 23

The coating shall not show any tendency for disbandment or blistering.
9.

FLANGE ADAPTORS
Flange adapters shall be installed as shown on the drawings to facilitate removal of valves
and other items for servicing/replacement.
The studs, nuts, bolts shall be stainless steel grade 316. The gasket shall be EPDM to ISO
4633 suitable for drinking water.
The flange pressure rating shall be as given in the Data Sheet or Particular Specification.
The coating shall be factory applied non toxic fusion bonded epoxy powder or Nylon based
polyamide 11 coating system complying with the requirements of AWWC 224 with normal
dry film thickness of 300 microns and minimum DFT of 250 microns.

10.

STEPPED COUPLINGS
Stepped couplings shall be used to connect the spigot ends of two pipes of different
nominal diameters.
The nuts, bolts and washers shall be stainless steel 316. The gaskets shall be EPDM to
ISO 4633 suitable for drinking water.
The coating shall be factory applied non toxic fusion bonded epoxy powder or a Nylon
based polyamide 11 coating system with normal dry film thickness of 300 microns and
minimum DFT of 250 microns.

11.

DISMANTLING JOINTS
Dismantling joints shall be installed as shown on the drawings to facilitate removal of valves
and other equipment for servicing/replacement. The dismantling joints shall be of the
tied/restrained type.
The nuts, bolts, studs, tie rods, washer shall be stainless steel 316. The gaskets shall be
EPDM to ISO 4633 suitable for drinking water.
The pressure rating of the flanges shall be as given in the Particular Specification.
The coating shall be factory applied non toxic fusion boded epoxy powder or a Nylon based
polyamide 11 coating system with normal dry film thickness of 300 microns and minimum
DFT of 250 microns.

12.

SPLIT TEES FOR UNDER PRESSURE CONNECTIONS

The sealing mechanism shall be by rubber ring set in a locating groove around the branch
opening and held firmly against the mainline pipe by the pressure of the opposite bolted half
or alternatively by full length rubber gaskets along the mating halves and at the separate
end flanges.

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 21

of: 23

The rubber gaskets shall be EPDM to ISO 4633 suitable for drinking water. The bolts, nuts,
washers shall be stainless steel 316.
The split tees shall be coated with non toxic fusion bonded epoxy powder or a Nylon based
polyimide 11 coating system with normal dry film thickness of 300 microns and a minimum
DFT of 250 microns.
13.

PUDDLE FLANGES OR SEALING FLANGES

Puddle flanges or sealing flanges shall be used in all situation where a ductile iron pipe is
cast into a chamber wall where restraint is not required. The sealing should be water tight
between the pipe and the opening through which it will pass. If the seal is made of two parts
jointed by nuts and bolts they should be galvanised.

14.

THRUST/ANCHOR FLANGES
Thrust/anchor flanges shall be used where D.I. pipes or fittings are cast into the chamber
wall and shall be designed to restrain the connecting valves or other equipment installed
inside the chamber.
Thrust/anchor flanges shall be integrally cast or factory welded on to the pipe piece. Bolted
or screwed on thrust flanges are not acceptable.
The coating to the thrust/anchor flange shall be similar to that of the pipe/fitting.
The position of the thrust/anchor flange shall be as shown on the drawings or determined
on site.

15.

POLYETHYLENE SLEEVES
Protective polyethylene sleeves shall be used with all D.I. pipes and fittings to be installed in
buried condition and shall be in accordance with ISO 8180. The polyethylene sleeve
manufacturer shall be ISO 9001: 2000 Quality Management System certified.
The polyethylene sleeve shall be black, resistant to the effect of ultra violet light, The
minimum nominal thickness of the sleeve shall be not less than 200m microns with a
maximum minus tolerance of 10%.
The material shall be made from a polymer with a melt flow index as measured according to
BS 2782, of 10 or less and a density in the range of 0.910 to 0.935 g/ml. The sleeve shall
be free from pinholes, gels, undispersed raw materials and particles of foreign matter. The
film may not contain more than 5% by weight of material other than polyethylene.
Polyethylene sleeving shall be stored in cool dry store away form direct sunlight or
excessive heat. Rolls shall be supplied individually packed in black polyethylene sacks and
clearly marked according to ISO 8150 clause 7.

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 22

of: 23

16.

VENDOR DOCUMENTATION
The CONTRACTOR shall furnish the following vendor data as a minimum, with his bid:

Catalogues/Brochures of the proposed manufacturer's.

Dimensional details of pipes and fittings.

Detailed material specifications.

Manufacturer's drawings, showing fittings dimensions.

Complete details of testing facilities available at manufacturer's works.

Local (UAE) agent name and address.

Outline of Quality Assurance Procedures in use.

Bids not accompanied by any of above-mentioned information/data shall be considered

incomplete, and liable to be rejected.

Client
Project:
Title:

project phase:

ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES

project:

document: W-P-SS-001

rev: 4

sheet: 23

of: 23