SPECIFICATION

SECTION 4.0 – SEWERAGE

4.1 Scope

This section covers the requirements of the supply, installation and testing of pipelines for
gravity sewers and force mains.

4.1.1 Reference Standards

The following standards are referred to in this section:-

BS 65 Vitrified clay pipes, fittings and joints

BS 437 Cast iron spigot and socket drain pipes and fittings

BS 1377 Methods of test for soils for civil engineering purposes

BS 4346 Joints and fittings for use with UPVC Part 1, 2 & 3 pressure pipes

BS 4660 UPVC joints and fittings

BS 5911 Precast concrete pipes and fittings for Parts 1, 2 & 3 drainage and
sewerage

BS 2484 Elastomeric joint rings for pipework and pipelines

BS 4505 Flanges and bolting for pipes, valves and fittings

BS 6572 MDPE and HDPE pipes

4.2 Materials

4.2.1 Materials for Gravity Sewer

Material for gravity sewer shall be of vitrified clay pipe (VCP) up to 300 mm diameter and
reinforced concrete pipe (RCP) for sizes above 300 mm in diameter as hereinafter
specified. Sulphate resistant cement shall be used in the manufacturer of concrete pipes
which are to be installed within 300 meters of a marine environment. The pipe strengths
for the various sizes of pipe required are to be detailed on the drawings and are based on
certain assumptions regarding bedding material.

4.2.2 Vitrified Clay Pipes (VCP) and Fittings

Vitrified Clay Pipes and Fittings shall be of extra strength, conforming the requirements of
BS 65: 1981 or of strength as suitable for the location proven by standard calculation of
loading. All vitrified clay pipes and fittings shall be furnished with rubber ring joints or
equivalent.

(a) Reinforced Concrete Pipe (RCP) and fittings

Pipes shall be reinforced concrete type, size, strength and quality as indicated on the
drawings or as specified. Pipe sections shall be in minimum lengths of 3 m or as
approved by the Engineer, except where shorter lengths may be required to meet
special conditions. Certificate of strength shall be supplied by the manufacturer.
Pipe shall be in accordance with BS 5911 : Part 1. Additional protection against
hydrogen sulphate attack shall be provided for all concrete pipes receiving sewage
which has been subject to more than six hours detention.

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(b) Marking of Concrete Pipe

The following shall be clearly marked on the pipe:

A. The date of manufacture.

B. The name or trademark of the manufacturer.

C. The specified strength.

D. Circular pipe with elliptical reinforcement shall have the letter “T” marked on
the inside at the top at the correct place to indicate the proper position when
laid.

(c) Workmanship and finish

Concrete pipe shall be free from fractures, large or deep cracks and surface
roughness. The planes of the ends of the pipe shall be perpendicular to their
longitudinal axis.

(d) Rejection of Concrete Pipe

Pipe shall be subjected to rejection on account of failure to conform to any of the

specified requirements or on account of any of the followings :-

i. Fractures or cracks passing through the shell, except that a single end crack
that does not exceed the depth of the joint shall not be caused for rejection. If a
single end cracks that does not exceed the depth of the joint exists in more than
10 percent of the pipe inspected, however, the defective pipe shall be rejected.

ii. Defects that indicate defective mixing and moulding.

iii. Surface defects indicating honeycomb or open texture.

iv. Spalls deeper than half the depth of the joint or extending more than 100 mm
around the circumference or spalls smaller than half the depth of the joint or
less than 100 mm around the circumference exist in more than ten (10) percent
of the pipe.

v. Exposed reinforcement which indicates that the reinforcement is misplaced.

(e) Joints for Concrete Pipe

All reinforced concrete sewer pipes shall have spigot and socket with a neoprene
gasket joint, or approved equivalent.

4.2.3 Material for Force Mains

Force main shall be of HDPE pipes unless instructed or approved otherwise. All pipes,
joints and fittings shall have a hydraulic pressure rating equivalent to twice the maximum
operating duty pressure.

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4.2.4 Unplasticised PVC (UPVC) Pipes & Fittings

Unplasticised UPVC pressure pipes shall comply with BS 3505. Joints and fittings for
pressure pipes shall comply with the relevant provisions of BS 4660 or BS 5481. Solvent
cements for jointing UPVC pipes shall comply with BS 4346: Part 3. For pipes and fittings
complying with BS 4660 solvent cement may alternatively comply with BS 6209. UK
Information’s Guidance Note (IGN) 4-31-01 dealing with UPVC pipes and fittings.

4.2.5 High Density Polyethylene Pipes (HDPE) & Fittings

HDPE pipes for force mains should be manufactured and supplied in accordance with BS
6572 for pipe with a maximum operating pressure of 12 bar. Pipe wall thickness of SDR
11 and SDR 17.6 are available pressure ratings of 10 bar and 6 bar respectively.

Joints should be either butt fusion welded or socket welded fusion on site with the removal
of internal beads created by the welding process.

Fittings shall be manufactured from HDPE unless otherwise specified or as shown on the
drawing.

Pipes may be laid by conventional open cut or narrow trenching with welding carried out
above ground and pipes lowered into place in the pre-prepared trench.

4.3 Workmanship

4.3.1 Handling and Storing Pipes

During storage, handling and transporting, every precaution shall be taken to prevent
damage to the pipe and fittings. Pipe shall be handled only by means of fabric slings, or
other approved methods used in accordance with manufacturer’s recommendations.
Dropping or bumping of pipe will not be permitted. Damaged pipe shall be replaced.
Pipes shall not be dragged over the ground and, if rolled, shall be rolled only over adequate
timbers to prevent damage.

Timber materials and operational gear shall be stored under cover. Pipes may be stored in
the open, but shall be placed on adequate timber to prevent damage to sheathing or sockets.
Pipes may be stacked one above the other up to three pipes high provided suitable
protective packing is placed between them. If any pipes of fittings show signs or corrosion
or deterioration during storage they shall immediately be treated by the Contractor as the
Engineer directs to arrest and prevent the corrosion.

4.3.2 Inspection at Time of Installation

Pipes and fittings including any sheathing, lining or protective paint work, shall be
inspected by the Contractor immediately before and after installation and any damage shall
be repaired by the Contractor before the pipe or fitting is installed or jointed as the case
may be. Any specified material required for the repair of pipe, sheathing or lining shall be
obtained by the Contractor from the pipe supplier and shall be used with due regard to his
recommendation. The Engineer may himself and without hereby relieving the Contractor
of any of his obligations, inspect and test the pipe and appurtenances by any means he
consider appropriate and any damage discovered by such inspection shall be repaired by
the Contractor as aforesaid. The Contractor shall remove from the Site any pipe or
appurtenance which in the opinion of the Engineer is so badly damaged as to be unfit for
incorporation in the Works.

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4.4 Trench Excavation

4.4.1 General Requirements

Trench excavation shall be carried out by such methods and to such lines dimension and as
shall allow for the proper construction of the Works in accordance with the Drawing and
requirements as specified under Section 4.3.3. Notwithstanding the foregoing, any trench
in rock shall be so excavated that clearance between the pipe when laid and the rock sides
and bottom of the trench is kept within minimum limits necessary to provide for the
specified thickness of bedding and / or for protection of the pipe. Bell holes and holes and
depressions for couplings, valves and the like be excavated the same distances below these
installations. Minimum trench width shall be as required for proper assembly and
inspection, but in no case less than the requirement indicated in the drawings. Maximum
trench width shall be no greater than as shown in the Drawings, Trenches shall have
vertical side support otherwise authorized by the Engineer. No length of trench excavation
shall be started before pipes and fittings to be laid in that length are available on the Site.

4.4.2 Alignment and Grades

The lines and level of trenches shall be in accordance with the design details shown
Drawings or as may be directed by the Engineer or his representative. Before commencing
trench excavations, the Contractor shall set out the proper route of the trench for approval
of the Engineer.

In the event that obstruction not shown on the plans are encountered during the progress of
the work, which will require alterations to the plants, the Contractor shall have the
authority to change the plans and effect the necessary deviation from the line and or grade
with the agreement of the Engineer. The Contractor shall not make any deviation from the
specified line and/or grade without the prior agreement of the Engineer.

4.4.3 Supporting Trench Excavations

The sides of trenches shall be vertical and must be adequately supported at all times when
the depth of excavation exceeds 1.2 metres, except in open land if approved by the
Engineer. Proprietary trenching systems and mechanised trenching methods such as
continuous bucket or wheel type excavators in suitable locations are to be approved by the
Engineer. However, the Contractor must adequately support all trench sides when using
such systems for the safety of workmen and the public and to protect the works.

If for any reason any portion of trench excavation shall give way, the Contractor shall
immediately inform the Engineer or his representative of the failure and shall suspend all
works in the immediate vicinity of the collapsed trench until the ground has been made
safe. The Contractor shall take all necessary remedial measures to stabilize the sides
including installation of additional shoring and strutting and the excavation and removal of
all soil hereby disturbed.

4.4.4 Battered Trench Sides

Where the Contractor elects and permitted by the Engineer to execute trench excavations
with bettered sides instead of providing support as aforesaid they shall be excavated to
stable slopes and heights at a slope of not steeper than one to one from a point 0.3 metre
above the top of the sewer pipe and to a less steep side slope where necessitated by ground
conditions.

The Contractor shall take the precautions to prevent flotation of pipes in locations where
open trench excavations may become flooded and these precautions may include the partial
refilling of the trench leaving pipe joints exposed for test of the joints.

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4.4.5 Control of Water

All excavation and placement of backfill and fill shall be carried out in the dry. The
Contractor shall furnish, install and operate all necessary machinery, appliances and
equipment to keep excavations free from water during constructions and shall dewater and
dispose of the water so as not to cause injury to public or private property or to cause
nuisance or a menace to the public. He shall at all times have on hand sufficient pumping
equipment and machinery in good working condition for all ordinary emergency, including
power failure and shall have available at all times competent workmen for the operation of
the pumping equipment. During excavation, construction of manhole, etc., installation of
pipelines and sewer, placing of structure and trench backfill and the placing and setting of
concrete, excavations shall be kept free of water. The Contractor shall control surface
runoff so as to prevent entry or collection of water in excavations. The static water level
shall be drawn down a minimum of 300 mm below the bottom of the excavations so as to
maintain the undisturbed state of the foundation soils and flow the placement of any fill or
backfill to the required density. The dewatering system shall be installed and operated so
that the ground water level outside the excavation is not reduced to the extent that would
damage or endanger adjacent structures or property.

4.4.6 Method of Dewatering

Before dewatering is started the Contractor shall indicate to the Engineer for record
purpose only with the Engineer the method, installation and details of the dewatering
systems he proposes to use.

4.4.7 Release of Groundwater

The release of groundwater to its static level shall be performed so as to maintain the
undisturbed state of the natural foundation soils, prevent disturbance of compacted fill or
backfill and prevent flotation or movement of structures pipelines and sewer.

4.4.8 Backfilling Trench Excavation

4.5 Backfilling

Trench excavations shall normally be refilled using suitable material selected from the
excavation. Soft material (free from stones greater than 50mm in size for pipes without
coatings and 25mm size for pipes with coatings) shall be deposited in 150mm layers and
thoroughly rammed with suitably shaped rammers working alternately on either side of the
pipe (particular care being taken to avoid damage to the pipe and any sheathing until the
soft filling has been carried up to at least 300mm above the top of the pipe. Where the
condition of the excavated material does not meet the above requirements, sand shall be
imported and used in place of the soft material mentioned above to a similar level above
the top of the pipe.

The remainder of the refilling may consist of coarse material (including broken rock from
excavation in rock) free from boulders and clods of earth larger than 150mm in size
provided that the compacted backfill is, in the opinion of the Engineer, sufficiently dense to
prevent material from the superimposed layers being washed into the voids in such backfill.
This coarse material shall be spread in layers of depth not greater than 200mm and be
thoroughly rammed by an approved mechanical rammer. The coarse filling is to be carried
up to the level at which (inroads and footpaths) surface reinstatement is to commence or
(elsewhere) to such level as with the surface reinstatement of the whole of the topsoil will
leave the finished work sufficiently 'proud' to allow for future settlement to the original
ground level. Hard material such as broken rock and original road metalling shall normally
be used only for the surface reinstatement of roads as specified, but where it is suitable and
available in sufficient quantity it may be used in place of or as well as the aforesaid coarse
material.

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4.5.1 Material for Backfilling

Should the material being placed as refilling, while acceptable at the time when approved,
become unacceptable to the Engineer due to exposure to weather conditions or due to
flooding or have become puddled, soft or segregated during the progress of works, the
Contractor shall remove such damaged, softened or segregated material and replace it with
approved material. To permit the proper consolidation of backfill in to the voids behind
trench sheeting and supports, trench sheeting shall be withdrawn gradually as backfill
progresses in depth and along the trench. On no account shall any excavated material be
dozed back when refilling trenches in roads and no backfilling shall be carried out unless in
the opinion of the Engineer, sufficient mechanical rammers are in operation on that portion
of the work.

4.5.2 Soft Refill Material - Special Measure

Where in the opinion of the Engineer sufficient supplies of the aforesaid material for trench
refilling cannot reasonably be obtained from excavations the Engineer may order the
Contractor :-

A. To carry out such work as may be necessary to sieve out stones, or

B. To excavate material from suitable borrow areas and transport it to the length of
trench to be refilled, and the Contractor shall do any or all of these things as directed.
No extra payment will be made to the Contractor for this work.

4.5.3 Compaction

Where necessary, the Contractor shall adjust the moisture content of the refill material
either by drying out or by adding water to assist the compaction of the material. During
compaction, the backfill shall have uniform moisture content equal to or a little above the
optimum moisture content recorded in the Compaction Test. Backfill shall be compacted to
a dry density of not less than 95 per cent of the maximum dry density when tested in
accordance with this Specification.

4.6 Pipe Installation Work

4.6.1 General

Unless specified otherwise, pipe shall be installed singly and shall not be jointed until after
they have been installed. All sewer and force main pipes shall have flexible joints. In the
case of force main, all above ground crossings, shall have flanged joints.

The pipe shall be accurately installed to the lines, levels, grades and positions set out by the
Contractor from design data on the Drawings. Pipes and specials which are required to be
fixed onto or built into other structures shall be positioned as shown on the Drawings.

Brackets, steelwork cradles and the like fixings shall be in accordance with typical details
shown on the drawings, or if not so detailed shall be as approved by the Engineer. Pipes
shall rest on a solid and even foundation or bedding for the full length of the pipe barrel.
Suitable excavation shall be made to receive sockets or collars. Except where directed or
shown otherwise, the minimum cover to the laid pipes, measured at the highest point at the
joint, shall be 1.2m in roadways and lm in open fields.

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The Contractor shall kept the interior of pipes clean and free from water, dirt, stones or
other foreign matter as installation proceeds. At the end of the day's work or whenever the
work ceases for any reason or other times when installation work is not proceeding, the
unfinished/open ends of pipes shall be securely closed or sealed off by a wooden or a tight
fitting plug or other approved stopper.

The Contractor shall take all necessary precautions to prevent the pipe from floating due to
water entering the trench from any source, and shall assume full responsibility for any
damage due to the cause. All pipelines adjoining concrete structures (including manhole)
shall have a mechanical (flexible) joint within or at 300mm of the outside face of such
structures.

The Contractor shall, after excavating the trench and preparing the proper bedding for the
pipe furnish all necessary facilities for properly lowered and placing sections of the pipe in
the trench without damage and shall properly install the pipe. The section of pipe shall be
fitted together correctly and shall be laid true line and grade in accordance with the bench
marks established by the Contractor.

The full length of the barrel of the pipe shall have a uniform bearing upon the bedding
material, but if the pipe has a projecting bell, suitable excavation shall be made to receive
the bell which shall not bear on the subgrade.

4.6.2 Pipe Laying

No pipe shall be rolled into placed for lowering into the trench except over suitable timber
planking free from roughness that is likely to damage any coatings, before laying, each
pipe shall be cleaned out and inspected for defects. Any defective, damage or unsound pipe
shall be rejected.

Before any pipe is lowered into place, the bedding shall be prepared so that each length of
pipe shall have a firm and uniform bearing over the length of the barrel. The pipes shall be
laid in straight lines, both in the horizontal and vertical planes, between manholes or, where
directed in the case of force mains and larger diameter sewers to regular curves.

Each pipe shall be plumbed to its correct line and direction and accurately sighted by
means of boning roads and sight rails fixed to secure posts which shall be set up and
maintained at each end of the sewer to be laid and not more than 46m apart. Sight rails
shall be clearly painted in contrasting colors and be not less than 150mm deep, straight and
level. Boning rods shall be of robust construction clearly painted and accurately made to
the various lengths required, the lower end being provided with a shoe of sufficient
projection to rest on the invert of the pipes as laid. The boning road shall be complete with
a vertical spirit level. Boning roads and sight rails shall not be removed until the pipeline
has been checked and approved by the Engineer.

Alternatively, approved laser beam instrumentation may be used for setting accurate line
and level.

Each pipe shall be carefully lowered onto its prepared bed by means of necessary slings
and tackle. A recess shall be left in the prepared bed to permit the sling to be withdrawn. If
the prepared bed is damaged the pipe shall be raised and the bed made good before pipe
laying is continued. Pipe shall be laid upgrade unless otherwise authorized by the
Engineer.

Any pipe which is not in true alignment, both vertical and horizontal, or shown any undue
settlement after laying, shall be taken up and relayed correctly by the Contractor at his own
expense, when so ordered by the Engineer. No pipe shall be laid which is damaged,
cracked, checked or spelled or has any other defect deemed by the Engineer to make it
unacceptable, and all such sections shall be permanently removed from the work.

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Where sub-soil water is encountered it shall be kept below the sockets when jointing by
pumping or other means. In no case shall pipes be jointed before being lowered into
position. If any damage should occur to any pipes through failure of the Contractor to
comply with these conditions, the damage shall be made good at the Contractor's expense.

Pipe shall be jointed in such a manner that the offset of the inside of the pipe at any joint
will be held to a minimum at the invert. The maximum offset at the invert of pipe shall be
one percent of the inside diameter of the pipe or 9.4mm whichever is smaller. Unavoidable
offsets shall be distributed around the circumference of the pipe in such a manner that the
minimum offset occurs at the invert. After the joints have been made, the pipe shall not be
distributed in any manner.

The interior of each pipe, after being laid, shall be thoroughly cleaned. Pipe will be
carefully inspected in the field before and after laying. If any caused for rejection is
discovered in a pipe after it has been laid, it shall be subjected to rejection. Any corrective
work shall be approved by the Engineer.

4.6.3 Closure and Short Sections

For the purpose of reducing the angular deflections at pipe joints and for closure sections,
the Contractor shall be permitted to install pipe sections of less than standards length.
Closing courses and short sections of pipe shall be fabricated and installed by the
Contractor as found necessary in the field. Where closing pieces are required, the
Contractor shall make all necessary measurements and shall be responsible for the
correctness thereof.

4.6.4 Pipe Bedding

The surface shall be firm and true to grade. If soft, spongy, unstable or similar other
material is encountered upon which the bedding material or pipe is to be placed, this
unsuitable material shall be removed and replaced with unsuitable dense crushed rock
bedding material.

Bedding shall be in accordance with details of the Drawings. Except where concrete is
specified bedding material supporting the pipe or conduit shall be gravel, disintegrated
granite, crushed aggregate, native granular material or other suitable material. Limestone
shall not be used under any circumstances.

Any trimming, granular bedding material shall be spread in the trench bottom and screened
with a template. The Contractor’s rate shall include for provision of suitable material for
granular bedding and also for removal and disposal of excess material arising from the
trench excavations due to the granular bedding.

Material for granular bedding shall meet the following requirements :-

BS Sieve Size Percentage Min. Passing Max.

19mm 100 -

9.5mm 80 90

4.75mm 10 25

2.36mm 0 15

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If through the Contractor’s neglect any trench bottom is excavated below the grade
shown on the plans, it shall be refilled to grade of pipe invert with bedding material,
thoroughly compacted into place.

4.6.5 Concrete Protection of Sewer Pipes

Where indicated on the drawings, the pipe shall be backfield, hunched or encased in
concrete in accordance with the details on the drawings. Concrete shall be of the class
shown on the drawings, 20 MPa or as specified. Such concrete shall not be placed until the
joints at each end of the pipe have been completed.

Each pipe to be encased shall be supported on at least two purpose made precast concrete
blocks, which shall be left in place and the full width and depth of concrete encasement
shall be placed and carefully tamped beneath the pipe followed at once by the addition of
the encasing concrete. Unformed surface shall be of spade finish. The pipe shall be
prevented from floating or other movement during concreting. Except where shown
otherwise or ordered by the Engineer the continuity of concrete backfill or encasement to
pipe with flexible joints shall be broken at each joint.

4.6.6 Temporary Bulkhead

The Contractor shall furnish and install complete all the necessary temporary bulkheads in
the pipeline used for backfilling purpose and shall remove such bulkheads upon completion
of the line.

Special Laying Methods: Jacking

The jacking method of pipe-laying shall be employed where indicated on the Drawings or
as necessitated by conditions or requirements of the relevant Authority.

Unless otherwise specified or as shown on the Drawings the method and equipment to be
used for this purpose shall be proposed by the Contractor but a detailed description of his
proposal as well as the safety measures which he will be taking shall be submitted to the
Engineer for prior approval before commencement of pipe-jacking works. Approval of the
Contractor’s proposal by the Engineer shall not relieve the Contractor of the responsibility
for making a satisfactory installation which meets the technical criteria set by the approving
authorities concerned. The Contractor shall take note that pipes and pipe joint used in pipe
installation by jacking method shall be supplied by one single approved manufacturer.

4.6.7 Vitrified Clay Pipe (VCP)

After the trench for the pipe has been excavated to the proper line and grade in the manner
specified herein, the pipe shall be laid therein in the following manner. Before lowering,
the pipe shall be inspected for defects. Any defective, damaged or surround pipe shall be
rejected. The faces of all spigot ends all shoulders in the hubs or sockets be true and
brought into firm contact and any lumps and excrescences on said faces shall be cut away
before the pipe is lowered into the trench.

The pipe shall be laid, without break, upgrade from structure to structure and with the
socket end upgrade. Whenever the work ceases for any reason, the unfurnished end of the
pipeline shall be securely closed with tight fitting plug or cover. The interior of each pipe,
after being laid, shall be thoroughly cleaned.

Mechanical compression joints for vitrified clay pipelines shall be assembled in accordance
with the manufacturer’s recommendations. Care shall be taken to insure that a tight
compression joint is effected upon assembly.

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4.6.8 Reinforced Concrete Pipe (RCP)

All pipe shall be carefully inspected and laid uphill structures to structure with the bells
upgrade and with the class identification marks on top. Pipe shall be bedded, true to line
and grade, with uniform bearing for the entire barrel length. All material shall be removed
from the interior of the pipes and the inner surface of the bell or collar and the outer surface
of the spigot ends shall be thoroughly cleaned so that good joints can be made. Pipe
sections shall be so laid and fitted together that the sewer will have a smooth and uniform
interior. The sewer shall be clean and unobstructed at the time of its completion and
acceptance and shall be true to the line and grade as shown on the plans and profiles.

4.6.9 Rubber Gasket Pipe Joints

After the subgrade has been prepared as specified, the rubber gasket shall be placed in the
groove on the spigot and the spigot end of the pipe then entered into the bell of the
adjoining pipe and forced into position. Care shall be taken to avoid twisting or cutting the
gasket when jointing the pipe. The inside surface of the bell shall be lubricated with a
compound recommended by the manufacturer which will facilitate the telescoping of the
joint.

4.6.10 Anchor and Thrust-Blocks for Force Mains

The Contractor shall construct all anchor and thrust blocks as shown on the Drawings and
standard details. In general, thrust blocks will be placed at all changes in pipe direction
greater than seven (7) degrees.

Each thrust block shall be designated to have a sufficient bearing area and shall be placed
so safely transmit to the surrounding point. Thrust devices shall be cast-in-place concrete
metal harness, or other suitable devices. Thrust blocks shall be of grade 20/20 Portland
cement concrete shall be placed between fitting and trench wall or trench bottom, as the
case may be.

The bearing faces of the block shall be placed against freshly cut and undisturbed trench
wall or bottom of sound material. If the trust exceeds the bearing value of the surrounding
soil, the soil shall be precompacted before placing concrete.

All concrete shall be kept behind the bells of fittings. Formwork shall be constructed
wherever necessary to confirm the concrete to the prescribed dimension for the block. All
form lumber shall be removed prior to testing.

4.6.11 Pipe Supports

Pipe supports and pipe hangers shall be of standard manufacture and provided as shown on
the design drawings and in compliance with the following general requirements. Piping
shall be supported independently from equipment to which it is affixed. All weight of
piping and contained fluids shall be transferred to a structural or foundation system through
the individual or combined use of bedding, pipe saddle supports, or overhead hanger
systems. A support shall be provided for each pipe at or near the point where it is
connected to machinery or valves. A support shall be provided for each valve and special
fitting.

4.6.12 Cutting Pipes

The Contractor shall be responsible for taking the measurements required to determine the
lengths of cut portions of pipes for insertion as closing lengths in pipelines. The pipe and
methods of jointing shall be such that the locations of fittings and lengths of pipe can be
adjusted in the field to suit field conditions and variations in stationing.

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A reasonable tolerance in the location of lines will be permitted by the Engineer. The
Contractor shall make all closures with suitable pipe and approved connections to
compensate for cumulative errors in pipeline installation.

The cutting of pipes for inserting specials, fittings or closure pieces shall be carried out in a
neat and workmanlike manner with an approved cutting machine without damage to the
pipe and so as to leave a smooth end at right angles to the axis of the pipe.

The Contractor shall take every precaution to ensure that both the measurements and the
cutting of pipes are to the accuracy required and should any errors occur the Contractor
shall remedy same as the Engineer directs.

4.6.13 Rubber Ring Joint

Rubber Ring Joints are for vitrified clay pipes and reinforced concrete pipes unless
otherwise specified or instructed by the Engineer. Rubber sealing rings for pipe jointing
shall comply with B.S. 2494 and shall in addition contain antioxidants. The hardness of the
rubber shall be such that the joint when made on the installed pipes will be watertight as
specified under any combination of working or test loads. Immediately before assembling
each joint incorporating a rubber ring seal, the rubber shall be inspected for cracks, every
part of the ring being deformed by hand to about 150mm radius. If under this deformation
any cracks are either revealed or initiated the ring shall be rejected, cut through completely
to prevent inadvertent use, and the matter reported forthwith to the Engineer. If more than
three successive rings inspected in this way are rejected the Contractor shall stop all pipe
jointing until the cause of the defect has been proved and remedied to the satisfaction of the
Engineer.

4.614 Flanged-Joint

Flanged Joints are rigid joints and are used in all cast iron pipes joints, all valves and
fittings connections and for pipelines above ground. They shall be properly laid level
before bolting and on no account shall drifts or podgers be used in the bolt holes. Flanged
bolts shall be carefully and evenly tightened in rotation to ensure even pressure on the joint
ring. The joint ring shall be in the form of flat strip 5mm thick medium rubber reinforced
with two ply flex fabric with dimensions conforming to BS 3063 and lying within the bolt
circle. Flanges shall be faced over the jointing surface with a tool mark finish having a
pitch of 1± 0.3mm; serrations may be spiral or concentric. Pipes having screwed on
flanges shall be sealed at the thread joint between the pipe and the flange by a sealing
compound suitable for use in sewers.

4.6.15 HDPE Pipe Joints

Joints shall be made by one of the following methods :-

(a) Butt fusion welding

(b) Compression type fittings
(c) Flanges

Butt fusion welding shall be carried out in accordance with the manufacturers instructions,
using the equipment recommended for the operation which shall ensure correct alignment
of the pipes and application of a controlled pressure to the surface being jointed. Ends to
be fusion welded shall be cut square and be clean and free from imperfections.

Compression type fitting shall be of metal or plastic and shall be specially made for use
with polyethylene pipes. Metal fittings shall be made from corrosion resistant materials.

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Flanges joints shall be formed by placing a mild steel backing plate against a HDPE stub
flange. The backfilling plate shall be protected with bituminous solution, it shall be drilled
to BS 4504 : PN16, gaskets shall conform to BS 2494.

4.6.16 Protection of Joints

A. Flanged Joints shall be reprimed and painted with aluminum (if above ground) and
two coats of heavy bodied black bituminous paint for joints below ground.

B. Mechanical Joints shall have similar protection as the Flanged Joints.

4.6.17 Changes In Line and Grade

In the event that obstructions not shown on the Drawings are encountered during the
progress of the work which will require alterations to the Drawings, the Contractor may
propose to change the Drawings and order the necessary deviation from the line or grade
shown. The Contractor shall not make any deviation from the specified line or grade
without the approval of the Engineer.

4.6.18 Deflection at Certain Joints

Where a change of direction to deflect force mains from a straight line, either in the vertical
or horizontal planes to avoid obstruction or where long radius curves are permitted, the
amount of deflection allowed shall not exceed that required for satisfactory connection of
the joint and shall be approved by the Engineer. Where a change of direction cannot be
made by deflection at the joints of ordinary straight pipes, bends shall be used. The
locations of such bends and other specials shall be indicated on the drawings and their
exact positions will be determined by the Engineer on the Site.

4.6.19 Stream and River Crossing

Work at any crossing of a watercourse shall be carried out as expeditiously as possible to

the satisfaction of the Engineer and any responsible Authority with the minimum
interference to the free flow of water in the watercourse. Details of any temporary works
which may affect the flow of the watercourse shall be submitted to the Engineer at least 14
days before starting work.

Where the pipeline passes underneath a river, stream or ditch, unless otherwise detailed on
the Drawings it shall be encased in concrete. The minimum thickness shall be 150mm.
Unless otherwise shown, the depth of cover shall not be less than 600mm from the bed of
the river, stream or ditch to the top of the concrete. The Contractor shall fill the trench in
both banks with rock fill or concrete up to levels as shown on the drawings. The extent of
this work may be varied to suit each individual crossing.

Unless otherwise ordered, the concrete encasement of the pipe shall extend at least to a
section vertically below the tops of the banks. Provide protection against erosion to the
banks by means of stone pitching or rip-rap.

4.6.20 Connection to Existing Sewer Mains

At the locations shown on the Drawings the Contractor shall connect to the existing sewer
main or existing manholes. The sewer connections may include back-drops, service
diversions, punching through the wall of the existing manholes and to construct new flow-
through fittings in each manhole base to accommodate the new sewer line as required.
Actual connection between the existing piping and new piping shall not be made until the
new work has been approved by the Engineer.

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 SPECIFICATION

4.7 Manholes

At each change of gradient or direction, at each intersection with other sewers and at such
other points as shown on the Drawings, a manhole shall be constructed to the form and to
the dimensions shown on the Drawings. Manholes are to be constructed in circular precast
reinforced concrete sections or brick construction as shown on the typical drawings.

The bases of all manholes are to be formed of concrete of the full thickness shown on the
Drawings. Channel inverts shall be accurately laid to meet pipe invert elevations at the
same time as the sewer pipes are laid, the bends being as ‘slow’ as possible by siting the
manholes “off-center” at changes in direction. Short lengths of pipe with flexible joints
shall be provided at entry and exit to manholes.

Precast concrete manhole sections shall conform in all respects to BS 556. The dimensions
of the chambers and the shafts shall be as shown on the Drawings. All joints in precast
manhole sections shall be made with cement mortar. Manhole floors shall be constructed
with concrete formed to the required shapes with concrete channel inverts including half
round concrete channels, bends, tapers, junctions and double junctions. The top of the in-
situ benching shall be sloped back at 1 in 12. Precast manholes shall be encased with
concrete as shown on the Drawings. Rough shuttering shall be used for the concrete
surround to manholes. All concrete are to be Grade 20/20 Portland cement concrete unless
otherwise shown on the Drawings or directed by the Engineer.

Provision shall be made for future sewer connections to manholes by providing a box-out
sealed with bricks where shown on the drawings or where ordered by the Engineer. Heave
duty cast iron covers, Grade 10, to BS 497 shall be laid with their frames bedded on the
precast concrete rings. Manholes covers generally shall be set to the road profile and be
flush with the road surface. Manhole covers located in unimproved areas shall be
constructed at an elevation to prevent the entry of surface water.

Where drop manholes are necessitated they shall be shown on the Drawings and shall be
formed where the upstream length of sewer enters a manhole at a higher level than the
manhole invert level. All pipes and fittings in drop connection shall be the same material
and of the same size as the connecting pipeline shown on the drawings. All manholes shall
be watertight on completion and where leakage is discovered the Contractor shall perform
such work and provide all materials as are necessary to render such faulty work watertight.
The Contractor should take the necessary measures to ensure that the manholes are not
used as rubbish and waste dumps. The Contractor shall keep pipelines and manholes clear
of such rubbish and debris.

4.8 Valves

4.8.1 Air Release Valves

Air Release Valves shall be installed at the locations shown on the Drawings or as directed
by the Engineer if designs are modified on site. The valve shall be of the type that
automatically releases air, gas or vapor under pressure during system operation. The valve
shall have a minimum 50mm inlet with a 12.5mm outlet and a 4.8mm venting orifice for a
maximum working pressure of 1.03 kPa. The overall height less Back Wash Accessories
shall not exceed 0.52m. Valve shall be constructed of cast iron body and cover, stainless
steel trim and float, with an adjustable Viton orifice button to insure positive seating. Back
Wash Accessories shall be furnished and assembled to the valve, consisting of an inlet shut-
off valve, blow-off valve, clear water inlet valve, rubber supply hose and quick disconnect
couplings.

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 SPECIFICATION

Where indicated on the drawing sewage air and vacuum valve valve be installed. The
sewage air and vacuum valve shall be of the type that automatically exhausts large
quantities of air during the filling of a system and allows air to re-enter during draining or
when a vacuum occurs. The valve shall have an inlet size of 50mm N.P.T. and a discharge
size of 50mm N.P.T. The over-all height less ‘Back-Wash Accessories’ shall not exceed
525mm. Valves shall be constructed of cast iron body and cover, stainless steel trim and
float, with a Buna-N seat for positive seating. ‘Back-Wash Accessories’ shall be furnished
and assembled to the valve, consisting of an inlet shut-off valve, clear water inlet valve,
rubber supply hose and quick disconnect couplings. All valves shall be rated at 150 PSI
maximum working pressure.

4.8.2 Sluice Valves

All sluice valves shall comply with BS 5163:1974 and shall be approved by the Engineer
before use.

They shall have a cast iron body, spindle of stainless steel or other approved material, gun-
metal nuts, gunmetal faces and glands and stuffing boxes bushed with gunmetal. Sluice
valves shall be capable of withstanding a pressure head of 25 bars unless otherwise
specified. The sluice valves shall include for all necessary extension spindles, brackets and
handwheels as shown on the drawings. The valves bodies shall be painted with a suitable
bitumen paint. All sluice valves are to be of the rising spindle type. Each valve shall close
in clockwise direction.

Sluice valves shall be properly fixed in the positions as shown on the design drawings or as
directed by the Engineer if changes are made on site. The Contractor shall provide all
necessary rubber flange joint rings, bolts, etc.

4.8.3 Check Valves

Check valves or reflex valves (or other types of non-return valves of approved equal) shall
be C.I. or D.I. The non-return valves with all stainless steel internals, able to withstand
pressures up to 25 bars and flanged to in accordance with B.S. 10, Table D.

Check valves shall have an unrestricted opening with an adjustable controlled closure rate
so that valve slamming is reduced to an absolute minimum upon instantaneous power
failure. Valves may be mounted vertically between 10 bar flanges. Body shall be cast iron
with baked on epoxy coating. Disc and shaft shall be stainless steel 18-8. It shall be
complete with hydraulic cushion chamber, counter-weight and oil accumulator for
hydraulic operations. Seat ring shall be replaceable and shall be Viton, Teflon or of
approved equivalent.

Valve manufacturer or supplier shall provide service covering both installation and start-up
and operator training. The manufacturer or supplier shall submit a certificate of suitability
warranting that the valve and equipment is suitable for the application shown in the
contract documents and includes all features, accessories and performance characteristics
as required by the plans, design and specifications.

4.8.4 Plug Valves

Plug valves shall be eccentric and equipped with resilient faced plugs and be of non-
lubricated type capable of handling abrasive and raw sewage. The plug valves shall have
flanged ends as shown. Valves shall be furnished with manual operators as a unit. Each
valve plug shall rotate 90 degrees from the pipe axis in which the valve is installed.

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 SPECIFICATION

Valves shall be satisfactory for applications involving throttling service and/or frequent
operation and for applications involving valve operation after long periods of inactivity.
Valves with operators shall be suitable for operation with the valve shaft in any position
with flow in either direction. Indicators shall be provided to indicate degree of opening.

Valves shall be non-lubricated, of PN 10 rating, with non-shock pressure differential acting

in either direction; at 1.8 bars differential across the valve. The valve will provide drip tight
shutoff. Valves shall be Dezurick or equal. Valves 75mm and above shall have bolted
bonnet design. Bodies shall be of semi-steel or nickel iron having 1 percent to 1.5 percent
nickel content. Valves shall have raised seats and all surfaces in contact with the plug face
shall have 90 percent pure nickel or epoxy coating.

Valves shall have an average tensile strength of 235 Mpa. Port Areas of valve sizes greater
than 100mm shall be at least 75 percent of full pipe area. Flanged valves shall be faced and
drilled to BS 4504: 1969 standard and shall have face-to-face dimensions of standard gate
valves. Valves shall have balanced plugs to assure low torque. Valves shall be equipped
with resilient plug facing to provide drip tight shut-off without use of sealing lubricants.
Even if small solids are trapped between the plug and seat, the resilient facing shall provide
tight shut-off and prevent seat damage. Resilient plug facings shall be neoprene, or other
suitable materials capable of handling abrasives and raw sewage.

Valves shall have heavy duty upper and lower guide bearings capable of resisting corrosion
and preventing binding. Machined bearings shall assure long lasting easy valve operation.
Lower Guide bearings shall be equipped with stainless steel bushings. Upper guide
bearings shall have stainless steel bushings. Valve bearings, shaft seals and seats shall
comply with the relevant British Standard. Valves shall have adjustable multiple ring seals
to protect bearing surface from line fluids and outside foreign material.

Valves shall be actuated by means of a lever for valves under 75 mm size and by enclosed
gear and hand wheel operator for valves 100 mm and larger. All valves shall be supplied
with operators which require less than 100 Nm torque for operation and indicators which
show degree of opening. Chain wheels with guides shall be furnished on all valves 1.8m or
more above floor levels with enough cadmium-plated chain furnished for operation from
floor level.

4.8.5 Testing Pipelines

The Contractor shall submit for the Engineer’s approval details of his proposed methods
and program for testing (including details of test equipment) and shall arrange for all tests
to be witnessed by the Engineer or other person appointed by the Engineer. The Contractor
shall provide all things necessary for carrying out testing and cleaning including pumps,
gauges, pipe connections, stop ends, and all other temporary works. Pipelines shall be
properly completed and supported before being put under test except as hereinafter
detailed.

No testing will be permitted until ten days after thrust blocks and other holding down
works have been completed. Trenches shall be left open prior to testing pipelines except as
permitted by the Engineer who may lay down certain restricting conditions.

In addition to any tests of individual joints or other interim tests which may be specified
elsewhere the Contractor shall submit all parts of the pipelines to a final test.
Notwithstanding the foregoing the Contractor may at any stage of construction, carry out
such other tests as he considers desirable to check materials and workmanship on the
pipeline but this shall not relieve the Contractor of his obligations to achieve successful test
under the Contract.

For gravity sewers, an examination by closed circuit television of completed lengths will be
considered adequate to ensure compliance with this Specification.

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 SPECIFICATION

4.8.6 Testing of Force Main (Hydraulic Testing)

A. When a suitable section of pipeline has been laid, jointed and partly backfield as
specified it shall be prepared for testing by sealing the open ends temporarily with
caps. For this purpose the contractor shall prepare “test end” units consisting of short
lengths of pipe permanently fitted with caps to the satisfaction of the Engineer.
These units shall be jointed to the section of pipe to be tested with a standard
coupling which can be easily removed when the tests have been completed thus
enabling the “test end” unit to be provided with a valved outlet complete with
pressure gauge to serve as an air relief vent or for use when filling the pipe lines with
water. All pressure gauges shall be tested by the Contractor before use. When one
end of a section to be tested commences at a sluice valve, the valve may be used in
place of the “test end” section to close this end of the section during test.

The ends of the section of pipe under test shall be braced to withstand the end thrust
which develops from water pressure; temporary thrust blocks shall be provided by
the Contractor for this purpose.

The thrust blocks specified for the pipeline shall be permanently constructed in place
and the concrete properly cured before the test are made. No temporary bracing will
be permitted in place of thrust blocks since the purpose of the test includes the testing
of permanent thrust blocks and fittings in addition to pipes.

B. The section of pipe to be tested shall be filled with water of fair quality, free from
sediment from a source approved by the Engineer. The water shall be introduced into
the pipeline through the valve in “test end” unit at the lower end of the pipeline.
During filling, provision shall be made for air to escape from all high spots in the
pipeline and from the valve in the upper 'test end" unit. If the pipeline is on a level
grade, it may be necessary to provide temporary tees and air valves on the main at
several points to ensure the escape of air. The tees shall be blanked off after the test
is applied.

If the main runs up-hill, the pressure gauge used during tests should be situated at the
bottom of the section, otherwise excessive pressure may be imposed upon the lower
part of the pipeline and there will be a risk of damage to anchorages designed to
withstand the specified test pressure. This pressure shall be applied by means of a
force pump at the highest convenient point on the main so as to minimise the
pressure against which the pump will have to operate.

The test section shall be completely filled with water for at least 24 hours prior to
testing to allow for absorption of water into the pipes and/or jointing material.

C. Water shall be pumped into the main raising the pressure slowly in increments of 1
bar, with pauses of one minute between each increment. Should any appreciable
drop in pressure be noted during one of these pauses the test shall be stopped until
the cause of the pressure drop has been investigated and rectified. The pipes shall be
tested to a pressure of 12 bars or 1.5 times the design operating pressure of the line
(whichever is the lower).

An engine driven pump may be used until 10 bars pressure is attained and thereafter
full test pressure shall be applied by a hand pump.

The pressure/strength test shall be considered to have been passed when the pressure
gauge shows no reduction from the test pressure during the period of ten minutes
after full pressure has been attained.

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 SPECIFICATION

D. The leakage test shall then follow. The pressure shall be reduced to 10 bars and
maintained as constant as possible for a period of twenty-four hours by pumping in
make-up water if necessary.

The leakage test shall be considered to have been passed if the measured quantity of
make-up water pumped into the pipe to maintain the test pressure does not exceed 0.1
litter per millimeter (mm) of pipe diameter per Kilometer of pipeline per day (24
hours) for each 3 bars of pressure applied.

E. Only sufficient backfilling of the trench to prevent snaking of the pipes shall be
allowed before the satisfactory completion of these tests detailed above.

F. Every section of the pipeline shall be tested and connected with all previously tested
sections so that no element of the pipe line is left untested.

G. All D.I. or other pipes and fittings within the Pump Station shall also be similarly
tested from strength and leakage, but adequate precautions must be taken by the
Contractor to additionally strengthen or secure joints, bends, tees, etc, so that they are
not damaged during the tests. All pipes and fittings which prove defective shall be
remedied or replaced and tested again as necessary to carry out the tests and shall
repair any damage resulting or caused by these tests at his own expense. Pumps shall
not be subjected to hydrostatic pressure during the tests.

4.8.7 Cleanliness of Pipeline

On completion of the sewers, manholes and pumping mains, they shall be cleaned out and
flushed with water. All silt, mortar, concrete, debris and other obstruction to be removed.
Prior to acceptance by the Engineer the Contractor shall prove all new sewer mains to be
clear of obstructions.

4.8.8 Maintenance of Pipe Installation Work

The Contractor shall inform the Engineer of the expiry date of the defects Liability Period
and arrange for the cleaning up and ventilation of the Works and the provision of all
necessary ladders, etc., required for inspection of the works by the Engineer accompanied
by the Contractor or his representative. Any defects resulting from faulty materials or
workmanship used in the execution of the Works shall be rectified by the Contractor at his
own cost to the satisfaction of the Engineer in accordance with the General Conditions of
Contract.

4.9 Connections to Premises

4.9.1 General Requirement

The Contractor is required to undertake the making of connections i.e. between the newly
constructed sewer and property boundaries. In most cases, the final stage of the connection
including all work on private premises will be undertaken by a licensed Plumber acting for
the Employer.

The Contractor will be required to provide a connection facility to all properties within the
boundaries of the project area as shown on the Drawings.

4.9.2 Forms and Type of Connection

A. The Contractor should refer to the Standard Detail Drawings which show typical
connection details.

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 SPECIFICATION

B. Generally, connections will be taken from a 150 mm dia. Oblique junction on the
main sewer and be laid to the property boundary as a 150 mm dia. Pipeline at a
uniform gradient.

C. All pipework laid between the household collecting sewer and property boundaries
will be undertaken by others.

D. Where allowance has to be made for pumped connections, these should be taken into
a manhole position and discharged at invert level. Alternatively, a short length of
gravity drain may be laid between the collecting sewer and the boundary of the
property terminating in a small inspection chamber to receive the pumped flow.

4.9.3 Construction of Connections

A. All gravity connections should be 150 mm minimum diameter.

B. They should be connected to the collection sewer by means of an oblique junction in

the direction of flow.

C. The minimum gradient at which the pipes may be laid is 2%. All pipes should be
given 100 mm thick nominal concrete protection under public roads. Changes of
vertical and horizontal direction may be accommodated by using 22.5 o ‘slow’ bends.

D. Unless otherwise specified, vitrified clay pipes will be regarded as the normal
material to be used but other pipe materials may be used provided that they are
manufactured and designed for the appropriate duty and that a suitable means is
provided to allow the householder to connect using conventional materials.

E. At the boundary, the connection should be scaled at a socket end using a VC plug and
marked with a plastic marker tape laid between the connection and ground level. A
permanent hardwood or concrete marker post should be placed in the ground over the
end of the connection and a survey record taken.

F. Care should be taken in the crossing of utility services and monsoon drains to ensure
that they are properly protected during the construction of the connection.

The advice and direction of the Engineer should be obtained for the crossing of
monsoon drains above channel invert level. It is assumed that this will be permitted
providing that the hydraulic capacity of the drain is not impaired.

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