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C. Pipe Handling

1. Protect pipe from excessive heat or harmful chemicals.
2. Handle pipe and use equipment needed to avoid gouging of the pipe

surfaces.

PART 2 - PRODUCTS

2.1

PHYSICAL PROPERTIES

A. Materials used for the manufacture of HDPE pipe and fittings shall meet the
following physical property requirements:

Property Unit Test Value
Procedure
Material Designation - PPI/ASTM PE 3408
Material Classification - ASTM D1248 IC 5 P34
Cell Classification - ASTM D3350 345464C
Density g/cm? ASTM D1505 >0.940
Melt Index g/10 min ASTM D1238 <0.15
Flexural Modulus psi ASTM D790 110,000 to <160,000
Tensile Strength at yield psi ASTM D638 3,000 to <3,500
Slow Crack Resistance hours ASTM F1473 >100
(PENT)
HDB psi ASTM D2837 1,600 @ 23°C
UV Stabilizer % Carbon Black | ASTM D1603 2 to 3
Elastic Modulus psi ASTM D638 110,000
Brittleness Temperature oF ASTM D746 <-180
Vicat Softening ot ASTM D1525 255
; Temperature
Thermal Expansion in/in/°F ASTM D696 1x 104
Hardness Shore D ASTM D2240 64

B. There shall be no evidence of splitting, cracking, or breaking when the pipe is

tested.

C. Ring Stiffness Constant (RSC) values for the pipe shall be 90 percent of the

nominal.

D. The pipe and fittings shall be homogenous throughout and free from visible
cracks, holes, foreign inclusions, or other injurious defects. The pipe shall be as
uniform as commercially practical in color, opacity, density, and other physical

properties.

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High-Density Polyethylene Pipe 15210 - 3 of 13

December 2017

E. Clean rework or recycled material generated by the manufacturer’s own
production may be used so long as the pipe or fittings produced meet all the
requirements of this Section.

2.2 PIPE AND FITTINGS

A. Dimensions

1. The nominal inside diameter of the pipe shall be true to the specified pipe
size in accordance with ASTM D2513. Standard laying lengths shall be 40
feet + 2 inches.

2. Fittings such as couplings, wyes, tees, adaptors, etc. for use in laying pipe
shall have standard dimensions that conform to ASTM D2513.

3. Pipe and fittings shall have the Standard Dimension Ratio (SDR) rating
indicated on the Drawings.

B. Pipe and fittings shall be produced by the same manufacturer from identical
materials meeting the requirements of this Section. Special or custom fittings
may be exempted from this requirement.

C. Pipe and fittings shall be pressure rated to meet the service pressure
requirements specified. Whether molded or fabricated, fittings shall be fully
pressure rated to at least the same service pressure rating as the joining pipe.

D. Molded fittings shall meet the requirements of ASTM D3261 and this
Specification. At the point of fusion, the outside diameter and minimum wall
thickness of fitting butt fusion outlets shall meet the diameter and wall
thickness specifications of the mating system pipe. Fitting markings shall
include a production code from which the location and date of manufacture
can be determined. Upon request, the manufacturer shall provide an
explanation of his production code.

E. Perforated pipe shall meet the same physical properties and requirements of
standard solid pipe. Hole spacing and orientation are presented on the
Drawing. Sections of perforated pipe shall be fused together with perforations
aligned between each section of pipe.

F. Marking
1. Each standard and random length of pipe and fitting in compliance with
this standard shall be clearly marked with the following information:
a. Manufacturer’s Name or Trademark;
b. ASTM Standard Designation;
c. Nominal Pipe Size;
d. Class & Profile Number;

File No. 3066.09 High-Density Polyethylene Pipe 15210 - 4 of 13 December 2017

e. Production Code, including Extrusion Date, and Lot or Batch
Number; and
f. SDR.

2.3 SOURCE QUALITY CONTROL

A. The pipe and fitting manufacturer shall certify that samples of his production
pipe have undergone stress regression testing, evaluation, and validation in
accordance with ASTM D2837 and PPI TR-3. Under these procedures, the
minimum hydrostatic design basis shall be certified by the pipe and fitting
manufacturer to be 1600 psi at 73.4°F and 800 psi at 140°F.

B. Material shall be listed in the name of the pipe and fitting manufacturer by the
Plastics Pipe Institute (PPI) in PPI TR-4 with the following Standard Grade

ratings:

73.4°F 140°F
Hydrostatic Design Basis (HDB) 1600 psi 800 psi
Hydrostatic Design Stress (HDS) 800 psi 400 psi

C. PPI material listing in the name of the resin supplier is not acceptable in
meeting this requirement.

D. As the basis of the acceptance of the material, the manufacturer will furnish a
certificate of conformance of these Specifications upon request. When prior
agreement is being made in writing between the purchaser and the
manufacturer, the manufacturer will furnish other conformance certification in
the form of affidavit of conformance, test results, or copies of test reports.

E. Physical Test Requirements

1. Sampling: The selection of the sample of pipe shall be as agreed upon by
the purchaser and the manufacturer. In case of no prior agreement, any
sample selected by the manufacturer shall be deemed adequate.

2. Sample size for flattening test will be one sample per size and class of
pipe per project.

3. Conditioning: Conditioning of samples prior to and during test shall be as
agreed upon by the purchaser and manufacturer. In case of no prior
agreement, the conditioning procedure used by the manufacturer shall be
deemed adequate.

F. Test Methods (to be completed by Manufacturer)

1. Flattening: Three specimens of pipe, a minimum of 12 inches long, shall
be flattened between parallel plates in a suitable press until the distance
between the plates is 40 percent of the outside diameter of the pipe. The
rate of loading shall be uniform and such that the compression is

File No. 3066.09 High-Density Polyethylene Pipe 15210 - 5 of 13 December 2017

completed within 2 to 5 minutes. Remove the load, and examine the
specimens for splitting cracking or breaking.

2. Pipe Ring Stiffness Constant: The pipe ring stiffness constant shall be
determined using procedures similar to those outlined in ASTM D2412.
The stiffness of HDPE pipe is defined in terms of the load, applied
between parallel plates, which causes 1 percent reduction of pipe
diameter. Test specimens shall be a minimum of two pipe diameters or 4
feet in length, whichever is less.

2.4 GASKETS AND HARDWARE

A. All gaskets shall be %-inch thick, full face Viton with a Shore A durometer
rating between 60 and 80.

B. Joint hardware shall be Type 304 stainless steel.
2.5 FITTINGS

A. Fittings shall be manufactured from polyethylene compound having cell
classification equal to or exceeding compound used in pipe to ensure
compatibility of polyethylene resins.

B. Provide factory-fabricated, dual containment fittings except as indicated
below.

C. Fittings shall be from same manufacturer as pipe being provided. OWNER may
allow substitution for approved material with use of flanged joint sections.

D. Dimensions of fittings conforming to standard dimensions and tolerances in
accordance with ASTM F2206.

E. Fittings shall have the same or higher pressure rating as pipe.

F. Markings
1. Manufacturer’s name or trademark
2 Nominal size
3. Type of plastic pipe (i.e., PE 3408)
4. Standard dimension ratio
5 Extrusion date, lot number or batch number

G. The Drawings do not show all fittings that may be required. CONTRACTOR to
provide all fittings required for a complete installation.

File No. 3066.09 High-Density Polyethylene Pipe 15210 - 6 of 13 December 2017

PART 3 - EXECUTION

3.1 FIELD QUALITY CONTROL

A. Pipe may be rejected for failure to conform to any of the following:

1.

We WN

Fractures or cracks passing through pipe wall, except single crack not
exceeding 2 inches in length at either end of pipe which could be cut off
and discarded. Pipes within one shipment shall be rejected if defects
exist in more than 5 percent of shipment or delivery.

Cracks sufficient to impair strength, durability or serviceability of pipe.
Defects indicating improper proportioning, mixing, and molding.
Damaged ends, where such damage prevents making satisfactory joint.
Damage due to handling or installation. Scratches and gouges exceeding
five (5) percent of the wall thickness shall be considered excessive, and
may be rejected by OWNER or the CQA Consultant.

B. Acceptance of fittings, stubs or other specifically fabricated pipe sections shall
be based on visual inspection at job site and documentation of conformance to
this Section.

C. Prior to backfilling, CONTRACTOR shall obtain as-built survey
information (location and elevation) for the installed pipe at 50-foot
intervals, any changes in grade, and the location of all installed fittings.

3.2 INSTALLATION

A. — Trench, backfill, and compact in accordance with Specification Section 02200.

B. Heat Fusion of Pipe

1.

2.

Weld in accordance with manufacturer’s recommendation for butt fusion
methods. The pipe manufacturer shall certify fusion operators.

Butt fusion equipment for joining procedures shall be capable of meeting
conditions recommended by pipe manufacturer including, but not limited
to, temperature requirements, alignment, and fusion pressures.

For cleaning pipe ends, solutions such as detergents and solvents, when
required, shall be used in accordance with manufacturer's
recommendations.

Do not bend pipe to greater degree than minimum radius recommended
by manufacturer for type and grade.

Do not subject pipe to strains that will overstress or buckle piping or
impose excessive stress on joints.

Branch saddle fusions shall be joined in accordance with manufacturer's
recommendations and procedures. Branch saddle fusion equipment shall
be of a size to facilitate saddle fusion within the trench.

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High-Density Polyethylene Pipe 15210 - 7 of 13 December 2017

10.

11.

12.

Before butt fusing pipe, inspect each length for presence of dirt, sand,
mud, shavings, and other debris or animals. Remove debris from pipe.

Cover open ends of fused pipe at end of each working day. Cap to
prevent entry by animals or debris.

Use compatible fusion techniques when PEs of different melt indexes are
fused together. Refer to manufacturer’s specifications for compatible
fusion.
Fusion welding shall not be performed when pipe ends are exposed to
precipitation. CONTRACTOR shall provide temporary welding shelter if
necessary.
All HDPE cuttings from pipe facing and drilling shall be removed from the
pipe network by CONTRACTOR prior to turning the Project over to
OWNER. CONTRACTOR shall clean the entire pipe network associated
with the Project if HDPE cuttings are encountered in the pipe network by
OWNER following completion of the project.
All interior butt-fusion weld beads shall be removed from the pipe
ie., all HDPE pipe must be de-beaded) in accordance with the
manufacturer's recommendations.

C. Flange Jointing

1.
2.

3.
4,

Use on flanged pipe connection sections.

Connect slip-on carbon steel backup flanges with galvanized nuts and

bolts.

Butt fuse fabricated flange adapters to pipe.

Observe the following precautions in connection of flange joints.

a. All fasteners and back-up rings shall be carbon steel below grade,
and zinc-plated steel above grade.

b. Align flanges or flange/valve connections to provide tight seal.
Require nitrile-butadiene gaskets if needed to achieve seal. Gaskets
are required for flange/valve connections.

c. U.S. Standard round washers as may be required on some flanges in
accordance with manufacturer’s recommendations. Bolts shall be
lubricated in accordance with manufacturer's recommendations.

d. Tighten flange bolts using a torque wrench in sequence and
accordance with manufacturer’s recommendations. CAUTION: Do
not over-torque bolts. CONTRACTOR shall use a torque wrench to
tighten all flange fasteners.

Pull bolts down by degrees to uniform torque in accordance with

manufacturer's recommendation.

Protect below grade bolts and flanges by covering with a 6-mil thick PE

wrap. Duct tape wrap to HDPE pipe.

Electrofusion couplers, where used, shall be installed per manufacturer’s

specifications. The outside diameter of the HDPE pipe and face shall be

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High-Density Polyethylene Pipe 15210 - 8 of 13 December 2017

prepared in accordance with manufacturer’s recommendations prior to
installing the coupler.

D. Pipe Placement

1.

2.
3.

a

™

10.
11.

12.

13.

Grade control] equipment shall be of type to accurately maintain design
grades and slopes during installation of pipe.

Remove all standing water in trench before pipe installation.

Unless otherwise specifically stated, install pipe in accordance with
manufacturer’s recommendations.

Maximum lengths of fused pipe to be handled as one section shall not
exceed 400 feet and shall be placed according to manufacturer’s
recommendations as to pipe size, pipe SDR, and topography so as not to
cause excessive gouging or surface abrasion. Pipe wall gouges deeper
than 3/16-inch shall be cause for rejection of the pipe.

Cap pipe sections longer than single joining (usually 40 feet) on both ends
during placement except during fusing operations.

Remove dirt or debris from inside of pipe before backfilling.

Notify ENGINEER prior to installing pipe into trench and allow time for
ENGINEER’s inspection.

Correct irregularities found during inspection.

Complete connections within trench whenever possible to prevent
overstressed connections.

Allow pipe sufficient time to adjust to trench temperature prior to testing,
segment tie-ins, or backfilling activity.

Install reducers adjacent to laterals and tees.

To reduce branch saddle stress, install saddles at slope equal to and
continuous with lateral piping.

Place in trench by allowing minimum 12 inches/100 feet for thermal
contraction and expansion.

Coordinate construction of pipes near/in access roads with OWNER to
limit impediment of OWNER’s operations or operations of other
contractors.

3.3. PIPE TESTING

A. General

1.

2.

The Contractor shall perform hydrostatic pressure tests after placement
in trench, in accordance with these specifications.

The total test time, including initial pressurization, initial expansion, and
time at test pressure shall not exceed eight hours. If the test is not
completed in eight hours, the pressure in the test section shall be
released and the section allowed to “relax” for at least eight hours before
initiating another test.

File No. 3066.09

High-Density Polyethylene Pipe 15210 - 9 of 13 December 2017

ut

9.

Pipe lines shall be pressure tested in presence of the CQA Consultant.
CONTRACTOR to provide ENGINEER with a minimum of 7 days’ notice
before performing the test.

Provide necessary connections between section of pipe being tested and
nearest available source of water or air supply, together with test
pressure equipment, meters, pressure gauge, other equipment, materials
and facilities necessary to make specified tests.

Owner will provide a source of water for testing.

Provide bulkheads, flanges, valves, bracing, blocking, or other temporary
sectionalizing devices as required to perform the tests safely.

Pipe to be tested shall be exposed in the trench, except that bends,
reduced pressure rated fittings and components should be buried or
restrained. Flange connections shall be visible to check for leaks.
Contractor shall notify on-site personnel of the testing schedule, and only
allow personnel required to perform the test in the test area for the
duration of the test.

Contractor shall provide a system without leaks.

B. Test all non-perforated HDPE leachate force main pipe and fittings. Test all
PVC pipe in the Sump Riser Building, installed in accordance with specification
section 15212 and 15310, using this procedure as well.

C. Preparation

1.

Remove or isolate valves, flow meters, and instruments that may not
withstand the required test pressure from within the test sections.
Reconnect pipes with temporary fittings. Vent isolated equipment.

Flush pipe with clean water until pipe section to be tested is clean and
free of dirt, sand, pipe shavings, or other foreign material.

Plug pipe outlets with test plugs, blind flanges or other devices suitable
for the test pressure. Brace securely to prevent blowouts. Verify test
pressure does not exceed any component of the pipe system.

Restrain or remove expansion joints.

Pressurizing equipment shall include a pressure regulator, set to avoid
over-pressurizing and damaging otherwise acceptable pipe.

D. Hydrostatic Pressure Testing

1.

2.
3.

Contractor shall use a hydrostatic test pump specifically designed for
performing hydrostatic pressure tests on pipe.

Clean potable water shall be used as the testing medium to fill the pipes.
Pipe shall be tested at 1.5 times the rated working pressure of the pipe or
the lowest rated pressure of any component of the system being tested.
In no case exceed maximum allowable pressure for any pipeline
component, including valves, fittings, and instruments.

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High-Density Polyethylene Pipe 15210 - 10 of 13 December 2017

8.

9.

Apply test pressure slowly, and once the test pressure has been reached,
allow the pressure to stabilize, without adding additional pressure. This
may take 2 to 3 hours.

Once pressure has stabilized, add additional water to achieve the test
pressure and begin the test.

After 1 hour, additional water shall be added to return to the test
pressure. If the volume of water required to achieve the test pressure
after 1 hour is less than shown in the table, then the pipe has passed the
pressure test.

The total test time, including the initial pressurization, initial expansion
and time at test pressure, shall not exceed eight hours. If the test is not
completed within that time, the test pressure shall be removed for at least
eight hours, prior to performing the test again.

If pressure test is not accepted, correct leaks or defects in the pipe and
retest.

Remove temporary sectionalizing devices after tests are complete.

E. Test Report

1.

2.

Pressure testing shall be documented using the test log provided as
Attachment 1 to this Specification.

CQA Consultant shall record the following information for each test.
Date of test.

Description and identification of piping system tested.

Type of test performed.

Test fluid.

Test pressure.

Results of test.

Type and location of leaks detected.

Corrective action taken to repair leaks.

Results of retesting.

Name of person performing test.

Tore me ae op

[END OF SECTION 15210]

P:\3000s\3066.09\Source Files\Type II App\Specifications\ Division 15 Specifications\15210 HDPE.docx

File No. 3066.09

High-Density Polyethylene Pipe 15210 - 11 of 13 December 2017

ATTACHMENT 1 TO SECTION 15210
HYDROSTATIC PIPE PRESSURE TEST LOG

Project No.:
Project Name:
SANBORN ||| HEAD , ,
- ; Project Location:
Building Trust. Engineering Succe.
Weather
Contractor: Test No.

Sanborn Head Personnel:

Person/Company Performing the Test:

Date of Test: Time of Test: Start: Finish:
Pipe Length: ft. Pipe Diameter: in. Pipe Material: Pipe SDR/Sch.::
Rated Working Pressure: Test Pressure:

Location/designation of pipe tested:

t Pe Pc Amount of
Time Pressure Gauge Pressure Make-Up Water Added
(hours) Reading Dro 1
(psig) (0) (gal.)
0
1
2
3
4
5
6
Pass Fail Retest? Yes No

Description/location of defects for failed test:

Test Procedure:

nf WNP

. Pressurize to 150 percent of rated pressure;
. Add make-up water each hour for three hours to maintain pressure;
. Test phase begins after the initial three-hour phase;
. After one, two or three hours add a measured amount of makeup water to return to the test pressure; and

. The amount of makeup water added to return to the test pressure must not exceed the amount in the

makeup water test values table on the back of this sheet.

Comments:

Signature:

File No. 3066.09

HDPE Pipe, Fittings, and Appurtenances 15210 - 12 of 13 December 2017