WSA01 2004 3 1 Pipeline PDF

WATER SERVICES ASSOCIATION
of Australia
Polyethylene Pipeline Code
WSA 01—2004
Third Edition
Version 3.1
Originated as WSA 01—1998
Previous edition WSA 01—2001

WSA 01—2004-3.1 2
ACKNOWLEDGMENTS
The WSAA Board would like to express its appreciation to WSAA and PIPA Members for
their contributions to the revision of this Code.
DISCLAIMER
WSAA Codes are published by the Water Services Association of Australia Inc. on the
understanding that:
The Water Services Association of Australia Inc. and individual contributors are not
responsible for the results of any action taken on the basis of information in the
Polyethylene Pipeline Code, nor any errors or omissions.
The Water Services Association of Australia Inc. and individual contributors disclaim all
and any liability to any person in respect of anything, and the consequences of anything,
done or omitted to be done by a person in reliance upon the whole or any part of the
Polyethylene Pipeline Code.
PUBLICATION DETAILS
Published jointly by:
Water Services Association of Australia Inc.
469 Latrobe Street
Melbourne Victoria 3000 Australia
ISBN 1 8760 8864 8
COPYRIGHT
Water Services Association of Australia will permit up to 10 percent of this Code to be
copied for use exclusively in house by purchasers of this Code without payment of a
royalty or giving advice to Water Services Association of Australia Inc. Water Services
Association of Australia will also permit some or all of the Standard Drawings to be copied
for use in contract documentation.
© Copyright 2004 by WATER SERVICES ASSOCIATION of Australia Inc. All rights
reserved.
3 WSA 01—2004-3.1
FOREWORD
The experience and usage of PE for water and sewer pipes in Australia is increasing.
HDPE sewer pipes have been installed since the 1980's and has a range of PE types for
rehabilitation of both water mains and sewers. The use of PE 63 and PE 80B pipes for
water service connections has been common since the 1990's. PE pipes and fittings are
increasingly being used for a range of new water supply and sewerage systems, including
recycled water and vacuum and pressure sewerage. Consideration is also being given to
taking advantage of the weldability of PE and using it to construct fully welded gravity
reticulation sewer systems, thereby limiting the likelihood of infiltration.
The first edition of the Polyethylene Code was based on a document developed by Water
Industry Technical Standards (WITS) with the assistance of R.J. LeHunt for use by the
Melbourne retail Water Agencies, and included the experience and results of an extensive
installation trial conducted by Sydney Water, together with the knowledge and experience
of other Water Agencies, especially South Australia Water.
The second edition of the Code introduced procedures for testing non-pressure pipelines
and guidelines for vacuum sewers, as well as extensive revisions of testing and
commissioning of pressure pipelines and other changes resulting from standards
development and experience with manufacturing, design and installation, testing and
commissioning of PE pipelines.
This third edition of the Code continues to build on the experience and confidence of the
urban water industry with use of PE pipelines. Revisions include:
(a) requirements for recycled water mains included e.g. colour, colour coding, storage,
pressure class etc;
(b) requirements for pressure and vacuum sewers included e.g. pressure class,
clearances;
(c) fitting design factors;
(d) amendments to jointing requirements;
(e) a completely revised general test procedures for pressure applications;
(f) comments on use of repair clamps;
(g) advice and limitations for squeeze-off;
(h) new stiffness class requirement for non-pressure applications;
(i) additional option for internal colour of non-pressure pipes;
(j) limitations on use of coils for gravity sewers;
(k) reference to new relining pipe standards;
(l) new prerequisites for training; and
(m) other editorial changes.
COPYRIGHT
WSA 01—2004-3.1 4
CONTENTS
Page
ACKNOWLEDGMENTS ............................................................................................... 2
DISCLAIMER ............................................................................................................... 2
PUBLICATION DETAILS .............................................................................................. 2
COPYRIGHT ................................................................................................................ 2
FOREWORD ........................................................................................................ 3
1 INTRODUCTION ....................................................................................................... 7
1.1 BACKGROUND ...................................................................................................... 7
1.2 PURPOSE .............................................................................................................. 7
1.3 SCOPE................................................................................................................... 7
1.4 REFERENCED DOCUMENTS ............................................................................... 8
1.5 FURTHER READING ........................................................................................... 10
1.6 DEFINITIONS....................................................................................................... 10
1.6.1 Squeeze-off .................................................................................................. 10
1.6.2 Purple ........................................................................................................... 10
1.7 ABBREVIATIONS................................................................................................. 10
2 PRESSURE PIPELINES.......................................................................................... 12
2.1 GENERAL ............................................................................................................ 12
2.2 COMPOUND DESIGNATION ............................................................................... 12
2.3 PIPE SIZES .......................................................................................................... 12
2.4 EQUIVALENT PIPE SIZES................................................................................... 12
2.5 PRESSURE CLASS ............................................................................................. 12
2.6 PIPELINE IDENTIFICATION ................................................................................ 15
2.6.1 Pipes............................................................................................................. 15
2.6.2 Pipe colour coding ........................................................................................ 15
2.6.3 Colour compounds........................................................................................ 15
2.6.4 Striping ......................................................................................................... 15
2.6.5 Buried appurtenances ................................................................................... 15
2.6.6 Surface fittings .............................................................................................. 16
2.6.7 Above-ground pipelines ................................................................................ 16
2.7 STORAGE ............................................................................................................ 16
2.8 DELIVERY INSPECTION ..................................................................................... 16
2.9 STANDARD LENGTHS ........................................................................................ 16
2.10 PIPELINE DESIGN............................................................................................. 17
2.10.1 System life .................................................................................................. 17
2.10.2 Structural .................................................................................................... 17
2.10.3 Surge and fatigue........................................................................................ 17
2.10.4 Fitting design factors................................................................................... 18
2.10.5 Pressure pipe design factors....................................................................... 19
2.10.6 Environment................................................................................................ 19
2.10.7 Crossings.................................................................................................... 19
2.10.8 Surface obstructions and clearances .......................................................... 21
2.10.9 Underground obstructions and services and clearances ............................. 21
2.11 INSTALLATION .................................................................................................. 24
2.11.1 Trenching and embedment ......................................................................... 24
2.11.2 Pipelaying ................................................................................................... 24
2.11.3 Jointing ....................................................................................................... 25
COPYRIGHT
5 WSA 01—2004-3.1
2.11.4 Pipeline anchorage ..................................................................................... 25

2.11.5 Tapping....................................................................................................... 25
2.12 WELD PRE-QUALIFICATION............................................................................. 26
2.12.1 Butt fusion................................................................................................... 26
2.12.2 Electrofusion ............................................................................................... 26
2.12.3 Quality plans ............................................................................................... 27
2.13 TESTING AND COMMISSIONING ..................................................................... 27
2.13.1 General ....................................................................................................... 27
2.13.2 Pre-Testing Procedures .............................................................................. 28
2.13.3 Test procedure selection............................................................................. 28
2.13.4 Basic pressure test (Visual) ........................................................................ 28
2.13.5 General pressure test (Technical) ............................................................... 29
2.13.6 Commissioning ........................................................................................... 30
2.14 MAINTENANCE.................................................................................................. 30
2.14.1 Post installation works ................................................................................ 30
2.14.2 Repairs ....................................................................................................... 30
2.14.3 Squeeze-off ................................................................................................ 31
2.15 ELECTRICAL SAFETY....................................................................................... 32
3 NON-PRESSURE PIPELINES................................................................................. 33
3.1 GENERAL ............................................................................................................ 33
3.2 COMPOUND DESIGNATION ............................................................................... 33
3.3 PIPELINE SIZES .................................................................................................. 33
3.4 STIFFNESS [SN] .................................................................................................. 33
3.5 COLOUR .............................................................................................................. 33
3.6 STORAGE ............................................................................................................ 33
3.7 STANDARD LENGTH........................................................................................... 33
3.8 FITTINGS ............................................................................................................. 34
3.9 PIPELINE DESIGN............................................................................................... 34
3.9.1 System Life ................................................................................................... 34
3.9.2 Structural ...................................................................................................... 35
3.9.3 Hydraulic....................................................................................................... 35
3.9.4 Environment.................................................................................................. 35
3.10 INSTALLATION .................................................................................................. 35
3.10.1 Trenching and embedment ......................................................................... 35
3.10.2 Pipelaying ................................................................................................... 35
3.10.3 Property connection sewers and maintenance shafts ................................. 35
3.10.4 Jointing ....................................................................................................... 36
3.10.5 Maintenance holes and maintenance shafts ............................................... 36
3.11 Weld PRE-QUALIFICATION............................................................................... 36
3.11.1 Butt fusion................................................................................................... 36
3.11.2 Electrofusion ............................................................................................... 36
3.12 Testing ............................................................................................................... 36
3.13 MAINTENANCE.................................................................................................. 37
3.13.1 Post installation connections....................................................................... 37
3.13.2 Repairs ....................................................................................................... 37
4 RELINING APPLICATIONS..................................................................................... 38
4.1 GENERAL ............................................................................................................ 38
4.2 MATERIALS ......................................................................................................... 38
4.3 PIPE 38
4.3.1 Nominal diameters ........................................................................................ 38
4.3.2 Length........................................................................................................... 38
4.3.3 Colour ........................................................................................................... 38
COPYRIGHT
WSA 01—2004-3.1 6
4.4 FITTINGS ............................................................................................................. 38

4.5 PIPELINE DESIGN............................................................................................... 39
4.6 INSTALLATION .................................................................................................... 39
4.6.1 General......................................................................................................... 39
4.6.2 Jointing ......................................................................................................... 39
4.6.3 Connections.................................................................................................. 39
4.7 RELINING TYPES ................................................................................................ 39
4.7.1 Sliplining ....................................................................................................... 39
4.7.2 Pipe cracking and moling .............................................................................. 40
4.7.3 Swagelining .................................................................................................. 40
4.8 TESTING.............................................................................................................. 40
5 PERSONNEL QUALIFICATIONS ............................................................................ 41

5.1 GENERAL ............................................................................................................ 41
5.2 WELDING............................................................................................................. 41
5.3 TRENCHLESS TECHNOLOGY ............................................................................ 42
APPENDIX A ...................................................................................................... 43
EQUIVALENT PIPE DIAMETERS .............................................................................. 43
APPENDIX B ...................................................................................................... 47
REFERENCES FOR USE BY DESIGNERS WHEN MANAGING THE RISK OF
INSTALLATION, OPERATION AND MAINTENANCE OF PE PIPELINE SYSTEMS IN
CONTAMINATED LAND............................................................................................. 47
APPENDIX C ...................................................................................................... 48
STANDARD DRAWINGS ........................................................................................... 48
C1 GENERAL............................................................................................................. 48
C2 LISTING OF STANDARD DRAWINGS ................................................................. 49
COPYRIGHT
7 WSA 01—2004-3.1
1 INTRODUCTION
1.1 BACKGROUND
ICI scientists discovered polyethylene (PE) in 1933 in the United Kingdom. Low density
polyethylene (LDPE) was first produced and marketed in 1945, followed by high density
polyethylene (HDPE) in 1955 and medium density polyethylene MDPE (PE 63, PE 80B and
PE 80C) in 1971. In more recent times higher performing HDPE compounds have been
added to the PE 80B range and a new compound of HDPE, PE 100, with strength
properties significantly higher than normal HDPE, has been produced and marketed.
PE 80B and PE 100 compounds are mainly used in the water industry. Pipes range in size
from DN 25 to DN 1600 with applications that include submerged ocean outfalls, water
reticulation, vacuum and pressure sewers, and pipelines to service properties.
1.2 PURPOSE
The WSAA PE Code is intended to guide water industry practitioners towards best practice
in the use of PE pipeline systems. Its adoption by the national water industry and
referencing in contracts should provide benefits to the Water Agencies and the urban
development industry in terms of product standardization, availability and price, installation
methods and controls and as a basis for curricula development for training programs. The
PE Code should be read in conjunction with other WSAA Codes such as WSA 02
Sewerage Code, WSA 03 Water Supply Code, WSA 04 Sewage Pumping Station Code
and WSA 07 Vacuum Sewerage Code, all of which in turn reference the PE Code.
The information outlined in this Code is progressively being incorporated into and
referenced by other national standards, codes and specifications which address the
design, construction, testing and commissioning, operation and maintenance of water and
sewerage networks and the relevant products and test methods.
This Code will also provide a focus for continuous improvement of best industry practice in
the use of PE pipeline systems especially as more experience is gained through their wider
adoption throughout the Australian and New Zealand Water Agencies.
The Code provides a mixture of mandatory and informative statements.
The mandatory requirements are a mixture of both prescriptive and performance
requirements. Overall, the Code provides “deemed-to-comply” solutions to the planning,
design and construction of pressure and non-pressure pipeline networks.
The information and guidance (informative text) contained in the Code has been
deliberately interspersed throughout the mandatory requirements to provide some context
and enable better understanding of the mandatory requirements. Informative text has been
italicised to enable clearer differentiation.
However, it is emphasised that the exact approach taken to all aspects of a particular
project is the decision of the Water Agency and Planners, Designers and Constructors
involved in each project. This Code provides technical information to aid in that process.
1.3 SCOPE
The Code consists of four main sections:
Section 2 PRESSURE PIPELINES
A general guide to water reticulation and sewage pressure mains focussing on PE pipeline
selection, design, installation, testing, commissioning and maintenance, as well as advice
on electrical safety.
COPYRIGHT
WSA 01—2004-3.1 8
Section 3 NON-PRESSURE PIPELINES

A general guide to gravity sewers focussing on PE pipeline selection, design, installation,
testing and maintenance.
Section 4 REHABILITATION USING POLYETHYLENE
A general guide to PE relining systems.
Section 5 PERSONAL QUALIFICATIONS
Personal qualifications and training programs to ensure that personnel involved in the
installation of PE pipe systems are competent. It includes the relevant units of competency
of suitable training packages and certification requirements for personnel involved in the
design, installation and maintenance of PE pipeline systems.
Although it may not always be considered essential, it is preferred that design and
operational staff undertake formal training as both safety and operational factors are
paramount to the welding process.
1.4 REFERENCED DOCUMENTS

The following documents are referred to in this Code:
AS
1345 Identification of the contents of pipes, conduits and ducts
2033 Installation of polyethylene pipe systems
2700 Colour standards for general purposes
4087 Metallic flanges for waterworks purposes
4181 Stainless steel clamps for waterworks purposes
AS/NZS
1260 PVC pipes and fittings for drain, waste and vent applications
1477 PVC pipes and fittings for pressure applications
2280 Ductile iron pressure pipes and fittings
2566 Buried flexible pipelines
2566.1 Part 1: Structural design of buried flexible pipe
2566.2 Part 2: Installation of buried flexible pipe. (under preparation)
4129 Fittings for polyethylene (PE) pipes for pressure applications
4130 Polyethylene (PE) pipes for pressure applications
4131 Polyethylene (PE) compounds for pressure pipe and fittings
4441(Int) Oriented PVC (PVC-O) pipes for pressure applications
4765(Int) Modified PVC (PVC-M) pipes for pressure applications
4798(Int) Polyethylene (PE) maintenance shafts
5065 Polyethylene (PE) and polypropylene (PP) pipes and fittings for
drainage and sewerage purposes
ISO 9000 Quality management and quality assurance Standards
ISO 9000.1 Quality systems—Model for quality assurance in design, development,
production, installation and servicing
COPYRIGHT
9 WSA 01—2004-3.1
ASTM
D 2321 Standard practice for underground installation of thermoplastic pipe for
sewers and other gravity-flow applications
F 894 Polyethylene (PE) large diameter profile wall sewer and drain pipe
F 1417 Standard test method for installation acceptance of plastic gravity
sewer lines using low-pressure air
BS EN
13566 Plastics piping systems for renovation of underground non-pressure
drainage and sewerage networks
13566-1 Part 1: General
13566-2 Part 2: Lining with continuous pipes
13566-3 Part 3: Lining with close fit pipes
13566-4 Part 4: Lining with cured-in-place pipes
NZS
7702 Colour standards for general purposes
POP
004 Polyethylene Pipe Compounds
006 De-rating requirements for fittings
007 Steel backing flanges for use with polyethylene pipe (PE) flange
adaptors
010A Part 1 Polyethylene Pressure Pipes—Design for Dynamic Stresses
010B Part 2 Fusion Fittings for use with Polyethylene Pressure Pipes—
Design for Dynamic Stresses
ISO
13953 Polyethylene (PE) pipes and fittings—Determination of the tensile
strength and failure mode of test pieces from a butt-fused joint
WIS
4-32-08 Specification for site fusion jointing of MDPE pipe and fittings
WSA
02 Sewerage Code of Australia
03 Water Supply Code of Australia
04 Sewage Pumping Station Code of Australia
07 Vacuum Sewerage Code of Australia
109 Water Industry Standard for Flange Gaskets and O rings
COPYRIGHT
WSA 01—2004-3.1 10
1.5 FURTHER READING

Manual for Polyethylene Pipe Systems for Water Supply Applications. Report No. FR 0386
July 1994 WRc plc.
POLIplex Polyethylene Pipe Design Textbook, Iplex Pipelines Australia Pty Limited, 1997.
Polyethylene Pipe & Fittings Technical Manual, Vinidex Pty. Limited, 1999. (CD Rom)
Plastic Pipes for Water Supply and Sewage Disposal, Lars-Eric Janson, Borealis,
Stockholm, 4th edition 2003.
PPI Handbook of Polyethylene Piping – The Plastic Pipe Institute, 1825 Connecticut Ave.,
NW Suite 680 Washington, DC 20009
Ref: Engineering Properties;
Pipe and Fittings Manufacturing;
Jointing Procedures;
Underground Installation;
Pipeline Rehabilitation by Sliplining;
Above Ground Applications and other titles.
1.6 DEFINITIONS
For the purpose of this Code the definitions given in WSA 02, WSA 03, WSA 04, WSA 07
and AS/NZS 3500.0 and those below shall apply.
1.6.1 Squeeze-off
The closing down or isolating of PE pipelines by pinching or squeezing the walls of the
pipe together.
1.6.2 Purple
A colour defined in accordance with AS 2700 (NZS 7702) as being no darker than P24
Jacaranda or P12 Purple and no lighter than P23 Lilac
1.7 ABBREVIATIONS
The following abbreviations apply in this Code:
° degrees
ABS acrylonitrile butadiene styrene
AC asbestos cement
AS Australian Standard
ASTM American Society for Testing and Materials
CI cast iron
CICL cast iron cement mortar lined
DI ductile iron
DICL ductile iron cement mortar lined
DIN Deutsche Norm (German Institute for Standardisation)
DN nominal size, in millimetres
EN European Norm
COPYRIGHT
11 WSA 01—2004-3.1
GRP glass reinforced polyester

HDPE high density polyethylene
ID internal diameter, in millimetres
ISO International Organisation for Standardization
LDPE low density polyethylene
m metres
mm millimetres
MAOP maximum allowable operating pressure
MDPE medium density polyethylene
MH maintenance hole
MS maintenance shaft
NZS New Zealand Standard
PE polyethylene
PIPA Plastics Pipeline Industry Association of Australia
PPI Plastics Pipe Institute
PN nominal pressure, in megapascals x 10
prEN draft European Norm
PVC polyvinyl chloride
PVC-U unplasticised polyvinyl chloride
QA quality assurance
RC reinforced concrete
SDR standard dimension ratio
SN nominal ring stiffness
UPVC unplasticised polyvinyl chloride
VC vitrified clay
WIS Water Industry Specification (UK)
WRc Water Research Centre (UK)
WSAA Water Services Association of Australia
COPYRIGHT
WSA 01—2004-3.1 12
2 PRESSURE PIPELINES
2.1 GENERAL
Pipes and fittings shall comply with AS/NZS 4130 and AS/NZS 4129, respectively.
2.2 COMPOUND DESIGNATION

PE 80B or PE 100 compounds to AS/NZS 4131 shall be used for all pressure pipes (Refer
to Table 2.1).
2.3 PIPE SIZES

Unless otherwise specified, pipe sizes (Refer to Table 2.1) shall be as follows:
(a) For potable water and recycled water mains, sizes DN 90, 110, 125, 160, 180, 250,
280, 315, 355, 450 and larger sizes as listed in AS/NZS 4130.
(b) For recycled water mains in cul-de-sacs, sizes DN 50 and DN 63.
It is now a requirement that looped mains be provided for potable water in cul-de-
sacs to reduce the likelihood of water quality complaints (Refer to Figure 4.3 of
WSA 03 .
(c) For property potable water and recycled water services, sizes DN 25, 32, 40 and 50.
(d) For sewer pressure mains, sizes DN 40 and larger as listed in AS/NZS 4130.
(e) For vacuum sewers, sizes DN 110, 160, 225 and 315; for service connections DN 90
and for sensor pipes DN 63.
2.4 EQUIVALENT PIPE SIZES

PE pipe is specified by its outside diameter in accordance with international standards
(ISO). Equivalent PE pipe sizes for commonly specified pressure pipes shall be adopted as
listed in Table 2.1 and Appendix A.
These equivalent sizes have been chosen from the sizes available in the material and
pressure class such that they have an equivalent internal diameter that satisfies hydraulic
requirements. There are several PE pipe sizes available that have no equivalent in
Table 2.1 (for example DN 110 and 160). These sizes may also be applicable to recycled
water, sewer pressure mains and rehabilitation applications.
2.5 PRESSURE CLASS

Pipes and fittings shall be:
(a) PN 10 or PN 12.5 or PN 16 (Refer Tables 2.1 and 2.3) for water mains;
(b) PN 12.5 or PN 16 for pressure sewers; and
(c) PN 12.5 for vacuum sewers.
The pressure class for pipes and fittings based upon designated risk factors shall be
determined in accordance with Clause 2.10.3 and AS/NZS 4130.
Lower pressure classes may be used for individually designed installations such as sewer
pressure mains, low-pressure areas and in rehabilitation applications.
For PN 16 installations, PE 100 provides the benefits of larger bore and consequently
higher flow rates than for PE 80B of the same pipe pressure class.
COPYRIGHT
13 WSA 01—2004-3.1
TABLE 2.1
PIPELINE DESIGNATION
PERMISSIBLE EQUIVALENT PE PIPE
COMMONLY SPECIFIED WATER
SIZE, PRESSURE CLASS AND PERMISSIBLE PE JOINT SYSTEMS
PIPE MATERIALS AND SIZES
COMPOUND TYPE
Material
Copper Bolted PE
Mean ID Mean ID Compound Butt
Type B DN DN PN Electrofusion Compression Mechanical Flange
mm mm Type Fusion
PVC-PN12/16 Fittings adaptors
DICL-K9
Copper 21-22 10
20 17 25 20-21 12.5 PE 80B/100 Yes No Yes
19-20 16
Copper 27-28 10
25 23 32 26-27 12.5 PE 80B/100 Yes No Yes
24-26 16
Copper 34-35 10
Not
32 29 40 32-34 12.5 PE 80B/100 Yes No Yes
acceptable
30-33 16
except in
Copper 42-44 10 special
40 36 50 41-42 12.5 PE 80B/100 Yes No Yes circumstances
39-41 16
Copper 53-56 10
50 48 63 51-53 12.5 PE 80B/100 Yes No Yes
48-51 16
(continued)
COPYRIGHT
WSA 01—2004-3.1 14
Material
Copper Bolted PE
Mean ID Mean ID Compound Butt
Type B DN DN PN Electrofusion Compression Mechanical Flange
mm mm Type Fusion
PVC-PN12/16 Fittings adaptors
DICL-K9
76-79 10
Copper 65 61 90 73-76 12.5 PE 80B/100 Yes No Yes
69-73 16
76-79 10
Copper/DICL 80 73/72 90 73-76 12.5 PE 80B/100 Yes No Yes
69-73 16
94-97 10
110 90-94 12.5 PE 80B/100 Yes Yes
85-90 16
106-110 10
PVC/DICL 100 102/104/ 125 101-106 12.5 PE 80B/100 Yes Yes
98 96-101 16
136141 10
160 130-136 12.5 PE 80B/100 Yes Yes
123-130 16
153-158 10
PVC/DICL 150 143/152/ 180 146-153 12.5 PE 80B/100 Yes Yes Acceptable only
153 138-146 16 for connection to valves,
Not
hydrant tees,
212-220 10 acceptable
hydrant bends
PVC/DICL 200 203/202/ 250 203-212 12.5 PE 80B/100 Yes Yes except for
and
204 192-203 16 emergency
flanged connections
maintenance
238-246 10 to other pipe systems
and
228-238 12.5 PE 80B/100 or
PVC/DICL 225 226/226/ 280 Yes Yes special
emergency maintenance
229 216-228 16 situations
situations.
268-277 10
256 242-256 16
302-311 10
313 273-289 16
382-396 10
391 346-366 16
COPYRIGHT
15 WSA 01—2004-3.1
2.6 PIPELINE IDENTIFICATION

2.6.1 Pipes
There is no international or Australian/New Zealand Standard standardised colour coding
for the identification of buried pipelines. For buried pipelines, “blue” has become the
default colour for potable water (e.g. refer to AS/NZS 4130), although for above-ground
pipelines “blue” indicates compressed air. For recycled water, the leading jurisdiction in the
use of recycled water is California where recycled water was first used in the 1890’s. The
current State of California Water Recycling Criteria (adopted in December 2000) requires
the use of purple pipe, which has been their practice for over 15 years. The Department of
Health, NSW, in its Guidelines for Urban and Residential Use of Reclaimed Water
subsequently adopted the colour “deep purple” for piping containing recycled water.
2.6.2 Pipe colour coding
The colour coding for identification of PE pipes for different applications shall be as
follows:
(a) Black pipe with blue stripes for potable water applications, except in recycled water
areas where blue or blue jacketed pipe is required for property potable water
services.
(b) Black pipe for pressure sewerage applications. If condition assessment using CCTV
inspection is anticipated, then black pipes with a co-extruded internal white or natural
liner should be used.
(c) Black pipe with purple stripes for recycled water reticulation mains and purple
jacketed pipe for recycled water property service pipes.
2.6.3 Colour compounds
Blue compounds shall comply with AS/NZS 4130.
Purple compounds shall contain sufficient quantity of pigment such that the colour of pipes,
stripes on pipe and pipe jackets manufactured from these compounds shall be as follows:
(a) no darker than P24 Jacaranda or P12 Purple, in accordance with AS 2700
(NZS 7702).
(b) no lighter than P23 Lilac, in accordance with AS 2700 (NZS 7702).
Compliance with the compound colour requirements may be evaluated by visual
examination against the relevant colour reference of AS 2700 (NZS 7702). In the case of a
dispute, the batch of pipes will need to have its colour ordinates measured. These
ordinates should be within the ordinates for the maximum and minimum colours of AS 2700
(NZS 7702) given, using the same colour measuring technique.
2.6.4 Striping
The blue or purple stripes shall be placed equidistant around the circumference of the pipe.
The stripes shall have a minimum width of 3 mm and shall be applied as follows:
(a) A minimum of four (4) stripes for DN 90 pipe and smaller;
(b) A minimum of six (6) stripes for DN 110 pipe to DN 315 pipe;
(c) A minimum of eight (8) stripes for pipe larger than DN 315.
2.6.5 Buried appurtenances
The colour coding of buried fittings, valves, hydrants, etc is not considered critical for
pipeline identification. Pipe fittings are generally black.
COPYRIGHT
WSA 01—2004-3.1 16
2.6.6 Surface fittings

For surface fittings on buried pressure pipelines the following markings shall be adopted as
appropriate to the size of the visible surface of the fitting as installed:
(a) for potable water refer to WSA 03;
(b) for recycled water, the letters “RW” or words “recycled water”;
(c) for vacuum sewers, the letters “VS” or words “vacuum sewer”; and
(d) for pressure sewers, the letters “PS” or words “pressure sewer”.
2.6.7 Above-ground pipelines
The identification of contents of above ground pipelines shall be in accordance with
AS 1345.
2.7 STORAGE
Pipe and fittings shall be stored as follows:
(a) All pipe shall be stacked in a manner to minimise pipe ovalisation.
(b) For black pipe with blue or purple stripes and for blue or purple jacketed pipe outside
storage shall be limited to a maximum of two years from the date of pipe manufacture
prior to installation.
(c) Fittings, and sealing materials shall be left in the original sealed cartons until used
and stored in secure areas away from direct sunlight. Fittings conforming to
AS/NZS 4129 have a storage life at least equal to black PE pipe.
For solid black pipe outside storage can be unlimited.
2.8 DELIVERY INSPECTION

PE is a tough resilient material that is relatively light and easy to handle although, like all
plastics, it is prone to damage through scoring by sharp objects. Careful packaging and
handling is required for successful delivery of pipes and fittings to site, especially when
transported over long distances.
All pipes and fittings shall be inspected for damage at the time of delivery.
The maximum allowable depth of scoring or abrasion of external surfaces shall be 10% of
the wall thickness or 5 mm, whichever is the less.
Unless otherwise agreed, fittings shall be supplied in sealed separate bags or cartons
together with any associated small items such as bolts, nuts, washers and gaskets.
The ovality requirements for PE pipe only apply at the time of manufacture and before
coiling. Ovality requirements are not be applicable to pipe of SDR >17.6.
Kinked or crushed pipe shall be rejected.
Coiled PE pipe when removed from the coil or drum will be oval and curved. The extent of
ovality and curvature will depend upon the ambient temperature, SDR, pipe diameter, coil
diameter and compound type. Although both ovality and curvature may reduce naturally
with time, special equipment is available to facilitate handling and jointing. Coiled pipe is
usually limited to a maximum of DN 125.
2.9 STANDARD LENGTHS

Unless otherwise specified, the industry standard lengths shall be:
(a) For coils, nominal lengths of 50 or 100 m.
COPYRIGHT
17 WSA 01—2004-3.1
(b) For straight lengths, nominal 12 m.

Other lengths (6, 15 and 20 m) may also be supplied to order. Check with manufacturers
for their nominated standard lengths. Check that longer lengths are transportable to site
and able to be handled on site.
2.10 PIPELINE DESIGN

2.10.1 System life
Selection of allowable stress is based on long term pressure testing in the laboratory and
regression analysis applied to the data obtained. The 50 year point is arbitrarily chosen for
this basis, as for all thermoplastics pipes. A factor is applied to the 50 year point in order to
provide the design stress.
It shall not be taken that either:
(a) the pipes weaken with time; or
(b) the predicted life is 50 years.
System life is dependent on many factors. If the design stress were used in relation to the
regression curve, predicted pipe life would be indefinite, not 50 years.
As with other materials, the life is dependent on manufacture, transport, handling,
installation, operation, protection from third party damage and other external factors.
Provided that PE pipeline system components are appraised and supplied to nominated
industry standards under third-party product certification systems, and provided pipelines
are designed and constructed correctly, then the likelihood of failure is minimised. For
correctly manufactured and installed systems, the actual life cannot be predicted, but can
logically be expected to be well in excess of 100 years before major rehabilitation is
required.
If a system life is to be assigned beyond 100 years, it shall be based on the likelihood of
failure arising from the above factors, not the pipe regression curve.
Pipe strength has been shown not to decrease with time—in fact, it increases slightly.
"Instantaneous" burst pressure after a period in service will be at least equal to that of new
pipe.
2.10.2 Structural
Pipeline structural design shall be in accordance with AS/NZS 2566.1.
In most normal installations where the pipe is installed in accordance with Code Standard
Drawings appropriate to the application, a structural design is not required. However, the
Designer should evaluate the possibility of negative head collapse.
2.10.3 Surge and fatigue
For non-pumped pipelines, where the system pressure varies only as a result of diurnal
pressure variations, the maximum design pressure shall not exceed the pressure rating of
the pipe and fittings.
For pumped pipelines, a surge analysis shall be carried out and the maximum surge
pressure under normal operating conditions shall not exceed the pressure rating of the
pipe and fittings.
Surge analysis of pipeline networks is complex and subject to ongoing research. Further
requirements for design for surge and fatigue are outlined in the appropriate Codes e.g.
WSA 03 and WSA 04. The pipe manufacturer may also be contacted for advice. However,
as a guide, the maximum surge pressure can be estimated by multiplying the MAOP by a
COPYRIGHT
WSA 01—2004-3.1 18
surge factor of 1.25. No adjustment for operating temperature need be applied for surge
and fatigue design.
For fatigue loading situations, the maximum pressure reached in the repetitive cycle shall
not exceed the pressure rating of the pipe and fittings. Fatigue re-rating factors for PE 80B
and PE 100 pipes and fittings shall be as shown in Table 2.2.
To select the appropriate pipe and fittings class for fatigue loading, the following procedure
shall be adopted:
(a) Estimate the likely pressure cycle amplitude, i.e. the maximum pressure minus the
minimum pressure.
(b) Estimate the frequency or number of cycles per day (or week or month etc) that are
expected to occur.
(c) Determine the required life and calculate the total number of cycles that will occur in
the design lifetime e.g. 100 years.
(d) From Table 2.2 determine the fatigue load factor for the number of cycles.
(e) Divide the pressure amplitude by the fatigue load factor to obtain the equivalent
operating pressure.
(f) Use the equivalent operating pressure to select the class of pipe and fitting required.
TABLE 2.2
FATIGUE RE-RATING FACTORS FOR PE 80B, AND PE 100 PIPES AND FUSION
FITTINGS
Total Cycles Approximate number of Factors Load Factors 13
cycles per day for
Pipes Fusion fittings
100 year life
PE 80B and PE 100 PE 80B and PE 100
12 12
36,500 1 1.00 1.00
100,000 3 1.00 1.00
300,000 8 1.00 1.00
500,000 14 0.95 0.95
1,000,000 27 0.88 0.88
5,000,000 137 0.74 0.74
10,000,000 274 0.68 -
50,000,000 1,370 0.57 -
NOTES:
1 Maximum allowable factor for fatigue loading pressure cycles.
2 Reproduced from Table 1 of POP010A and Table 1 of POP010B. For further information refer to PIPA
Industry Guidelines
2.10.4 Fitting design factors

Where fabricated sweep bends, tees and other fittings for use with PE pipe to
AS/NZS 4130 are proposed, the fittings shall be evaluated. Unless performance and test
data is provided to support alternative values, weld factors and geometry de-rating factors
as outlined in POP006 shall be used to re-rate the fitting.
This aspect is particularly important where larger diameter fittings e.g. >DN 180 are
required to be fabricated from pipe. Smaller diameter moulded and electrofusion fittings
generally are designed to account for geometry factors and further re-rating is not required.
COPYRIGHT
19 WSA 01—2004-3.1
2.10.5 Pressure pipe design factors

The design factor used to determine the nominal pressure rating, PN, for Series 1 PE pipes
is 1.25. For calculation of MAOP for Series 1 pipes with increased design factors refer to
AS/NZS 4130. Unless otherwise agreed, design factors for pressure applications shall be
in accordance with Table 2.3.
Based on installation conditions, the maximum operating pressure shall be multiplied by
the relevant factors to produce a risk considered MAOP for pipe class selection.
As the temperature to which the PE pipe is exposed increases above the reference
temperature (20°C) the long-term hydrostatic strength decreases. Consequently, the pipe
PN rating shall be factored to suit the operating temperature as described in Table 2.3.
The design factors nominated are intended to take into account uncertainty and risk factors
associated with pipeline installation.
Table 2.3 is not intended to cover every conceivable situation. Where there is doubt, the
designer should contact the Water Agency for advice.
2.10.6 Environment
PE is resistant to many chemicals, but is susceptible to chemical attack and/or permeation
by petroleum products and certain solvents (For further information refer to AS 2033
Appendix A, Iplex Pipelines POLIplex Textbook and Vinidex Polyethylene Manual.
Where pressure pipelines are to be installed in suspected contaminated ground, specific
soil sampling shall take place to identify reagents in the ground and surrounding
groundwaters. Where contaminants deemed to be damaging or capable of permeating PE
are identified, the risk of using PE pipe systems shall be carefully evaluated.
Where PE pipe is specified, only fully welded PE systems shall be used. Where leaching of
contaminants into the pipe alignment may re-occur the PE pipe shall be contained within
an impervious sealed conduit.
The references listed in Appendix B may be used by design consultants and constructors
to manage the risk of installation, operation and maintenance with PE pipeline systems in
contaminated land.
The properties of PE make such pipelines particularly suitable for areas subject to ground
movement due to expansive clays, seismic forces, mining subsidence or compaction of
filled sites.
At low temperatures PE maintains its good characteristics such as impact strength such
that in many parts of the world that experience below freezing temperatures (below –18°C)
PE is the preferred pipe material.
2.10.7 Crossings
Pressure main crossings of roads, railway lines, creeks and underground services shall, as
far as practicable, be at right angles. Mains should be located and designed to minimise
maintenance and crossing restoration costs.
COPYRIGHT
WSA 01—2004-3.1 20
TABLE 2.3
PRESSURE PIPE DESIGN FACTORS
Condition Installation Factor Index

Fluid Water 1.0 f0
Domestic sewage 1.0
1
Industrial sewage 1.0
Soil, Fluid or −20 <t ≤−10 Refer manufacturer f1
Pipe −10 <t ≤0 0.6
Temperature
0 <t ≤20 1.0
Average t°C
20 <t ≤30 1.1
30 <t ≤35 1.25
>35 Refer manufacturer
Location Open field 1.0 f2
Based on Minor country road shoulder 1.0
minimum depth
of cover Major country road shoulder 1.0
specified in Minor country road—under pavement 1.1
AS/NZS 2566.1
Major country road—under pavement 1.2
Residential—paved and unpaved nature strip 1.0
(footpath)
Residential roadway—under pavement 1.1
Major urban road—under pavement 1.2
Commercial/Industrial paved and unpaved 1.1
nature strip (footpath)
Commercial/Industrial roadway—under 1.2
pavement
Central Business District 1.4
Private land—easement 1.0
Above ground 1.0
Submarine crossings 1.4
Installation Standard trenching 1.0 f3
Method Plough-in 1.1
Slip line with back grouting 1.0
Slip line without back grouting 1.2
Pipe cracking - with liner pipe in-situ 1.0
Pipe cracking - with liner pipe removed 1.2
NOTES:
1 Where contaminants capable of damaging PE compounds are identified the risk of using a PE system
shall be carefully evaluated.
2 Choose only one factor from each condition;
3 This Table applies to PE 80B and PE 100 pipe with a life expectancy of >100 years;
4 Pumped installations require further design consideration, refer to PIPA Industry Guidelines;
5 Work examples are also shown in AS/NZS 4130; and
6 Design Factor F = f 0 x f 1 x f 2 x f 3
COPYRIGHT
21 WSA 01—2004-3.1
2.10.8 Surface obstructions and clearances

Surface obstructions shall be located during the initial survey and inspection of the site and
through enquiries to local government and other service utilities.
Dimensions of obstructions at the surface might be different from their underground
dimensions.
For pressure mains located close to existing structures such as foundations for brick walls
and buildings, the ongoing stability of the structure needs to be maintained. The location
shall be clear of the “zone of influence” of the structure foundations to ensure that the
stability of the structure is maintained and that excessive loads are not imposed on the
pipeline.
Use Table 2.4, as a guide for minimum clearances.
TABLE 2.4
MINIMUM CLEARANCE FROM STRUCTURES
Pipe diameter Clearance to wall or building

DN mm
<100 600
100 – 150 1000
200 – 300 1500
>375 2000
2.10.9 Underground obstructions and services and clearances

Underground services and other obstructions such as power conduits/cables, gas mains,
drains, telecommunication conduits/cables, oil/petrochemical pipelines and the
underground portions of surface obstructions (tree roots, pits, etc) may affect the proposed
alignment of the pipeline both in plan and in level. Where the pipeline crosses other
services, the depth of those services shall be determined. Services outside the project
area may also affect the pipeline layout.
Details of large diameter sewers, drains and water mains shall be obtained from the
relevant Water Agency. Excavation may be required to determine the exact location and
depth of all underground obstructions. Agreement on clearances shall be reached with the
relevant service owner before the design is adopted.
Dial Before You Dig, a ‘One Call System’ to locate underground utility services, operates in
all states and territories. The number to call nation-wide is 1100. Nevertheless, hand
excavation (pot-holing) is recommended to determine the exact location and depth of
underground obstructions during design and again immediately prior to excavation.
When using trenchless technology installation, clearances of pipelines from other utility
services shall not be less than those clearances required for pipelines laid in an open
trench.
Clearance from other service utility assets shall be maximised wherever practicable.
Minimum vertical and horizontal clearances are shown in Tables 2.5, 2.6 and 2.7. Services
shall cross at 90° if possible, but not less than 45°.
Assets owned by other service utilities, existing and proposed, shall be considered when
selecting the pipeline location. Alignment of all service utility assets shall be shown on the
Design Drawings. Other utility assets that may be hazardous and require additional care
shall be noted on the Design Drawings.
COPYRIGHT
WSA 01—2004-3.1 22
TABLE 2.5
1
CLEARANCES BETWEEN WATER MAINS AND UNDERGROUND SERVICES
Minimum horizontal clearance
mm 2
Utility Minimum vertical clearance
(Existing service) New main size mm
≤DN 200 >DN 200
Water mains 600 600 500
>DN 375
3
≤DN 375
3
Gas mains 300 600 150 - low pressure gas mains
300 - high pressure gas mains
3
Telecommunication 300 600 150
conduits and cables
Electricity conduits 500 1000 225
and cables
3 4
Drains 300 600 150
5 5 4
Sewers 1000 /600 1000 /600 500
6
Kerbs 150 600 150 (where possible)
NOTES:
1 Includes potable and recycled water mains
2 Vertical clearances apply when water mains cross one another and other utility services, except
in the case of sewers when a vertical separation shall always be maintained, even when the
main and sewer are parallel. The main should always be located above the sewer to minimise
the possibility of backflow contamination in the event of a main break.
3 Clearances can be further reduced to 150 mm for distances up to 2 m when passing installations
such as poles, pits and small structures, providing the structure is not destabilised in the
process.
4 Water mains should always cross over sewers and stormwater drains. For cases where there is
no alternative and the main must cross under the sewer, construction shall be in accordance
with Standard Drawing WAT–1211.
5 When the sewer is at the minimum vertical clearance below the water main (500 mm), maintain
a minimum horizontal clearance of 1000 mm. This minimum horizontal clearance can be
progressively reduced to 600 mm as the vertical clearance is increased to 750 mm.
6 Clearance from kerbs shall be measured from the nearest point of the kerb. For water mains
≤ DN 375 clearances from kerbs can be progressively reduced until the minimum of 150 mm is
reached for mains ≤ DN 200.
COPYRIGHT
23 WSA 01—2004-3.1
TABLE 2.6
CLEARANCES BETWEEN PRESSURE SEWERS AND UNDERGROUND SERVICES
mm 1
(Existing service) Pipeline size mm
≤DN 200 >DN 200
2
Gas mains 300 600 150
2
Telecommunication 300 600 150 - low pressure gas mains
conduits and cables 300 - high pressure gas mains
and cables
2 3
Drains 300 600 150
2 3
Sewers 300 600 500
3
NOTES:
1 Vertical clearances apply when pipelines cross other utility services, except in the case of water mains
when a vertical separation shall always be maintained, even when the pressure sewer and water main
are parallel. The pressure sewer should always be located below the water main to minimise the
possibility of backflow contamination in the event of a pressure main break.
2 Clearances can be further reduced to 150 mm for distances up to 2 m when passing installations such
as poles, pits and small structures, providing the structure is not destabilised in the process.
3 Clearance from kerbs shall be measured from the nearest point of the kerb. For pressure sewers
≤ DN 375 clearances from kerbs can be progressively reduced until the minimum of 150 mm is reached
for mains ≤ DN 200.
COPYRIGHT
WSA 01—2004-3.1 24
TABLE 2.7
CLEARANCES BETWEEN VACUUM SEWERS AND UNDERGROUND SERVICES
mm 1
(Existing service) Pipeline size mm
≤DN 200 >DN 200
2
Water mains 300 600 150 for vacuum sewers
500 for pressure mains
2
Gas mains 300 600 150 - low pressure gas mains
300 - high pressure gas mains
2
Telecommunication 300 600 150
conduits and cables
and cables
2 3
Drains 300 600 150
2 3
Sewers 300 600 500
3
NOTES:
1 Vertical clearances apply when pipelines cross other utility services, except in the case of water mains
when a vertical separation shall always be maintained, even when the pressure main and water main
are parallel. The pressure main should always be located below the water main to minimise the
possibility of backflow contamination in the event of a pressure main break.
2 Clearances can be further reduced to 150 mm for distances up to 2 m when passing installations such
as poles, pits and small structures, providing the structure is not destabilised in the process.
3 Clearance from kerbs shall be measured from the nearest point of the kerb. For pressure mains
≤ DN 375 clearances from kerbs can be progressively reduced until the minimum of 150 mm is reached
for mains ≤ DN 200.
2.11 INSTALLATION
Installation of PE pipelines shall be in accordance with AS/NZS 2566.2.
Typical installation details for PE pipelines are shown in Standard Drawings WAT–1102,
WAT–1104, WAT–1105 of WSA 03.
2.11.1 Trenching and embedment
The trench and embedment requirements for plastics pipes outlined in Standard Drawing
WAT–1201 of WSA 03 shall apply.
2.11.2 Pipelaying
PE has a high coefficient of thermal expansion. PE pipes shall be installed to allow for the
difference in ambient temperature and the transported water or the in-ground temperature.
To minimize residual stress in the pipe, where practicable, the pipe shall be allowed to
stabilise at approximately the service temperature before final connection and back filling.
Detectable tape shall be installed in the trench along the top of the pipe unless otherwise
agreed by the Water Agency.
PE pipe located directly under roads, tram or rail lines shall be installed in accordance with
the asset owner’s requirements. Only fully welded joints, or single length pipe shall be
used.
COPYRIGHT
25 WSA 01—2004-3.1
'Plough in' type installations should be considered on their merits with respect to the
affects of 'spring back', ground conditions suited to PE pipe embedment, obstructions and
environmental considerations.
2.11.3 Jointing
For pipe sizes up to and including DN 90, joints shall be the compression or electrofusion
type complying with AS/NZS 4129. For new installations of pipe in diameters greater than
DN 90, butt welding or electrofusion coupling jointing shall be used. Only trained and
certified welders shall perform weld jointing of pipelines (Refer to Section 4). Spigot and
socket fusion welding shall not be permitted. Electrofusion systems shall permit manual
operation and be limited to the long bodied, 4.0/4.7 mm diameter single pin connections
conforming to the requirements of AS/NZS 4129.
Butt welding between PE 80B and PE 100 or the same SDR shall be permitted. Pipes of
different SDRs shall only be joined using electrofusion fittings.
Flanged fittings shall comply with AS/NZS 4129. Only full-face flanges complying with the
bolting details of AS 4087, Figure B2 shall be permitted for hydrant installations. A typical
arrangement for hydrant installation is shown on Standard Drawing WAT–1409. Sealing
gaskets complying with WSA 109 shall be used in all flanged joints.
Where PE pipe is to be connected to other pipe materials, valves or other fittings or where
there is a requirement for future disassembly, a flange adaptor, or a PE stub flange or
other approved end-thrust resistant fittings shall be used. The backing plate or backing
flange, bolts, nuts and washers shall be manufactured from Grade 316 stainless steel.
Shouldered end joints of the split metal housing type used in mining applications shall not
be permitted.
Mechanical compression joint fittings larger than DN 90 and complying with AS/NZS 4129
may be used for temporary services and special site conditions where it is impractical to
use a welded joint.
Where PE stub flanges are used in conjunction with a metallic flange, only raised faced
flange faces shall be used (Refer to WAT–1313 of WSA 03).
2.11.4 Pipeline anchorage
Where the jointing system does not have sufficient axial strength capability, anchorage at
bends, tees, reducers and dead ends shall be provided to resist the forces in accordance
with WSA 03. Installation techniques for anchor blocks shall be in accordance with the
relevant standard drawings of WSA 03.
Electrofusion joints, butt weld joints and compression fittings that comply with
AS/NZS 4129 can develop the full axial strength of the pipe and in buried applications do
not require thrust blocks to resist internal pressure forces at bends, tees, reducers, offsets,
dead ends, etc.
2.11.5 Tapping
Service tapping sizes shall be DN 25, DN 32, DN 40 and DN 50.
Service isolating valves at the main (ball valves) for DN 25 and DN 32 shall not be installed
for main sizes DN 180 and less unless otherwise required by the Water Agency.
Electrofusion welded tapping saddles shall be used at all times with new installations of PE
pipe.
Where the use of electrofusion tapping saddles is determined impractical by the project
manager, mechanical tapping saddles complying with AS/NZS 4129 may be used for:
COPYRIGHT
WSA 01—2004-3.1 26
(a) tapping PE minor mains (<DN 63);

(b) rehabilitation installations using PE in sizes up to and including DN 180; and
(c) connections to existing PE mains and above-ground PE mains.
Where mechanical tapping saddles are used, a minimum spacing of 500 mm between
tappings shall be maintained and tapping shall not be performed closer than 500 mm from
the termination of the PE pipeline.
Tapping of curved PE pipe shall take place only at the top of the pipe to minimise stress
around the tapping hole. Where dry tapping is performed, a plug cutter shall be used, and
all swarf removed. Under pressure tapping shall be permitted only with systems that utilise
plug cutters that retain the PE pipe wall plug within the cutter. Where welded tapping
systems are used, the assembly shall be allowed to fully cool naturally before tapping.
Tapping of straight pipe sections may take place on the side of the pipe.
2.12 WELD PRE-QUALIFICATION

2.12.1 Butt fusion
Before factory and field butt welding, pre-qualification of the welding procedure shall be
obtained. The following information shall be submitted to the Water Agency or project
manager for acceptance:
(a) all details of the works for approval prior to commencing work;
(b) the welding procedures to be used;
(c) the welding equipment to be used;
(d) the name and certification details of the certified welder;
(e) test results of the pilot welds to confirm the test specification requirements;
A pilot weld for each welding machine, pipe diameter, wall thickness and material type with
a record of the parameter values for each weld shall be made.
Pilot welds shall be tested in accordance with ISO 13953. To be accepted, the weld under
test shall fail in a ductile mode. The test pieces shall be retained for examination by the
project manager.
2.12.2 Electrofusion
Before factory and field electrofusion welding, including tapping saddles/bands, pre-
qualification of the welding procedure shall be obtained. The following information shall be
submitted to the Water Agency or project manager for acceptance:
(a) all details of the works for approval prior to commencing work;
(b) the welding procedures to be used including the following;
(i) standard fusion time;
(ii) standard cooling time;
(iii) welding equipment to be used, including control box details;
(iv) surface preparation of pipe surfaces to be welded and clamping arrangements;
(v) the name and certification details of the certified welder;
(vi) a pilot weld for each welding machine, pipe diameter, wall thickness and
material type with a record of the parameter values for each weld; and
(vii) test results of the pilot welds to confirm the test specification requirements.
COPYRIGHT
27 WSA 01—2004-3.1
The pilot welds shall be tested in accordance with Clause 3.6.4 of AS/NZS 4129.
2.12.3 Quality plans
A quality plan shall be prepared to demonstrate ongoing quality of welds and submitted to
the project manager. The quality plan shall address the maintenance, servicing and
calibration of equipment; inspection and testing, comprising inspection of goods received
and used on site, surface preparation of pipe surfaces to be welded, clamping
arrangements, final inspection and testing, and shall include a sampling plan for on site
welding, and inspection and test records.
For butt welds, it is recommended that at least one weld at the start of each day of welding
be tested; depending on the joint type, diameter and other risk factors, the frequency of
weld testing may be increased or reduced at the discretion of the Water Agency or project
manager.
For electrofusion welds, it is recommended that at least one weld in 20 be chosen at
random for destructive testing; the frequency of weld testing may be reduced at the
discretion of the Water Agency or project manager.
It is also recommended that quality records for each weld, numbered and located on a plan
of works, be retained for at least 6 years from the date of installation.
For guidance on welding procedures, equipment and quality assurance refer to UK Water
Industry Specification WIS 4-32-08.
2.13 TESTING AND COMMISSIONING

2.13.1 General
Pressure testing PE pipes may require special processes since they may continue to
expand significantly throughout the test period. When a PE pipe is sealed under a test
pressure there may be decay, even in a leak free system, due to the creep response and
stress relaxation of the PE material. Due to this material behaviour, standard pipe testing
procedures used for other pipe materials such as DI and steel, may not be suitable for PE
pipe.
The following factors can affect a PE pipe pressure test:
(a) length of section and pipe diameter;
(b) test pressure, rate of pressurisation and duration of the test;
(c) presence of air;
(d) relative movement of mechanical fittings;
(e) level of support from pipe embedment;
(f) accuracy of test equipment;
(g) ambient temperature changes during testing;
(h) presence of fittings and other materials in the test section; and
(i) the presence of leaks.
Long test sections may incorporate a large number of joints that should be checked for
leakage. The longer the test section the harder it is to locate a leak. Pipes above about
DN 250 cause additional effects to further complicate the test process. Where site or
production reasons require longer lengths to be tested, radio links between test operatives
to minimise the test duration should be employed.
COPYRIGHT
WSA 01—2004-3.1 28
2.13.2 Pre-Testing Procedures

Test pressures shall not exceed the design safety factor for the material and compressed
air testing shall not be permitted for pressure pipe.
Pre-testing procedures include the following:
(a) All required temporary and permanent thrust blocks shall be in place and all concrete
adequately cured.
(b) All bolted joints shall be left exposed to allow for re-tensioning during or after testing.
(c) Compacted embedment and backfill shall be placed to leave exposed all joints,
service connections and valves wherever practicable.
(d) Safety barriers shall be placed where required.
(e) The test duration shall be planned to be 15 minutes or no more than 45 minutes.
(f) The test equipment shall be placed in position and checked for satisfactory operation.
(g) The pump shall be of adequate size to raise and maintain the test pressure.
A pump that is too small may increase the test duration or if too large it may be
difficult to control the pressure.
(h) Two calibrated test gauges shall be used to cross check gauge accuracy.
(i) The pipeline shall be filled from the lowest point making sure all air is removed at
high point appurtenances e.g. air release valve, hydrant etc;
A firm foam swab may be used ahead of the fill water to assist air removal especially
where the pipeline undulates. Extract the swab at the high point hydrant or washout.
(j) The test section shall be left to stabilise overnight or for at least 2-3 hours if this is
not possible.
2.13.3 Test procedure selection
The objective of the pressure test is to test the jointing and fittings, not the material
capability.
Unless otherwise specified, the basic pressure test (visual) shall be used for installations
using both standard trenching and rehabilitation techniques. The general pressure test
(technical) shall be used for the remaining installations and in the case of dispute when
using the basic pressure test. With a safety factor of 1.25 for PE coupled with relatively flat
regression curves, the maximum test pressure and test duration for testing shall be
reduced whenever there is elevated (>20ºC) temperatures during testing (refer to f1 in
Table 2.3).
2.13.4 Basic pressure test (Visual)
The visual pressure test procedure shall be as follows:
(a) A test pressure of 1.25 times the maximum operating pressure shall be applied and
the test section isolated by closing the high point air release valves and the pump
feed valve;
(b) The test section shall be visually inspected for leakage at all joints especially bolted
joints, all fittings, service connections and ball valves;
(c) Pressure gauges shall be checked to ensure that pressure has not fallen dramatically
indicating an undetected leak;
(d) Any detected leak shall be repaired and the section retested;
COPYRIGHT
29 WSA 01—2004-3.1
(e) Where no leak is detected, open high point appurtenances and depressurise to slowly
drain the line into an approved waterway and make good all connection points.
(f) The location of the test section, the water temperature, test pressure and duration,
the date and the test results shall be recorded.
2.13.5 General pressure test (Technical)
2.13.5.1 General
The WSA 01-2001 method was based on the WRc method, which has been further
modified by G.P. Marshall et al. The method is known to have failed pipelines that were not
leaking, whereas the proposed method is simpler and has been used successfully since
1989 for LDPE, HDPE, and MDPE pipelines with lengths up to 3,000 m and diameters up
to 800 mm.
Both the WRc and modified methods were based on constant wall strain, resulting in stress
relaxation and consequent pressure decrease. These methods relied upon broad
assumptions concerning soil support, pipe material modulus, and air entrapment. i.e. the
pass/fail criteria for the pressure decay curves were dependent upon these assumptions.
Consequently, these methods were found to be unreliable as an assessment of pipeline
integrity.
Regarding pipe material modulus, the value is stress, time, and temperature dependent,
involving further guesswork. In addition, the PE 80B and PE 100 materials cover a wide
range of moduli, even for the outdated assumptions of MDPE for PE 80B and HDPE for
PE 100. Within these material categories we now have PE 80B HDPE, bimodal as well as
MDPE, and, for PE 100, we have HDPE.
In relation to field pressure testing, a generic modulus can no longer be assumed for
PE 100, as the introduction of low sag materials has meant a wide range of values even
within the HDPE category. Estimation of soil support over pipeline length involves even
more guesswork.
The WSA 01—2003 method proposed is not only simple and proven, but does not involve
the guesswork and potential unjustified penalties to installers of the current method.
A procedure for pressure testing PE pipelines has been developed in Scandinavia and is
outlined in “Plastics Pipes for Water Supply and Sewerage Disposal” by Prof. Lars-Eric
Janson, and PIPA Technical Paper “Field Pressure Testing”. It is specified in
AS/NZS 2566.2 and Swedish Water and Wastewater Works Association specification “VAV
P78”.
The test procedures set out below are based on these documents.
2.13.5.2 Test principle
For plastics pipes that are subjected to internal pressure, there will be a progressive drop
in that pressure due to stress relaxation.
Accordingly, it may be difficult to assess whether a pipeline is leaking or simply subject to
stress relaxation.
In order to overcome this difficulty, this method is based on the principle that if the
pressure is held constant, there will be a linear relationship between hoop strain and
logarithmic time.
Variables such as pipe stiffness and soil compaction are irrelevant, as the test result is
based on actual performance during the test.
Temperature may be considered constant, as with other test methods, unless special
conditions exist.
COPYRIGHT
WSA 01—2004-3.1 30
2.13.5.3 Test procedure

Maximum system test pressure (STP) shall be at least 1.25 times the maximum working
pressure of pipeline but not to exceed 1.25 times MAOP of lowest rated pipe/fitting in line.
Test the pipeline as follows:
(a) Raise pressure to STP, close off main and allow to settle for at least 12 hours. During
this period, pressure will fall as a result of pipe expansion.
(b) Using water of the same temperature as that in the pipeline (± 3°C) restore and
maintain STP
(c) Measure and record water volume added at 2h, 3h, 4h, and 5h from start.
(d) Conclude test 5 hours after commencement.
For optimum test protocol, the following tolerances are recommended:
(i) Water volume: ± 10D litres, where D = pipe nominal diameter in metres.
(ii) Time: ±1 min.
(iii) Pressure: ± 1 kPa.
Suggested tolerances are included even though the current method does not include
tolerances. Accordingly, they are included as recommendations only.
(e) Calculate the water volume added between the second and third hour, ∆V(3h-2h) and
the volume added between the fourth and fifth hour, ∆V(5h-4h).
(f) Calculate Vall = 0.14.L.D.H (ref. AS/NZS 2566.2, Section 6.3)
where:
Vall = Volume makeup allowance in litres/hour
L = Test length in km
D = Pipe nominal diameter in metres
H = Average test head over pipeline length in metres
(g) Test passes if ∆V(5h-4h) ≤ 0.55 ∆V(3h-2h) + Vall.
(h) Record the location of the test section, the water temperature, test pressure and
duration, the date and the test results.
2.13.6 Commissioning
The flushing and disinfection methods in WSA 03 shall be adopted for PE pipe. These
methods may be adapted to meet particular PE installation conditions, eg. pre-chlorination
of sliplined mains.
2.14 MAINTENANCE
2.14.1 Post installation works
For post installation tee insertion in pipe up to DN 90, compression fitting assemblies shall
be used. For pipe larger than DN 90, either electrofusion saddles or electrofusion slip
couplings or mechanical slip couplings that comply with AS/NZS 4129 shall be used.
Because of the general absence of anchor blocks in PE pipe systems, caution should be
exercised when specifying the use of non-end thrust resistant fittings such as wrap-around
stainless steel flanged off-take clamps for post installation works.
2.14.2 Repairs
For pipe up to DN 90, repairs shall be undertaken using compression couplings.
COPYRIGHT
31 WSA 01—2004-3.1
For pipe above DN 90, repairs shall be performed using electrofusion slip couplings,
compression fittings conforming to AS/NZS 4129 or wrap around stainless steel clamps
complying with AS 4181 (Refer to caution in Clause 2.14.1). Mechanical repair couplings
(Gibault type couplings) using a compressed circular rubber ring shall not be used for
repair of PE pipelines.
Stainless steel wrap around clamps provide no axial restraint. In some circumstances the
installation of these clamps may need to be accompanied by the installation of anchor or
thrust blocks. Some axially restrained stainless steel couplings up to DN 160 can be used
with out anchor blocks.
2.14.3 Squeeze-off
2.14.3.1 Background
The use of PE pipe is an attractive proposition particularly for smaller diameter pipelines
given that the squeeze-off technique can be used for isolation in the event that
maintenance is required. By using PE there is no need for any isolation valve either at the
pipeline or along any connecting service pipe. However, if replacement of the squeezed-off
PE pipe section is required, then the proposition becomes decidedly less attractive.
In the U.K., the water industry does not mandate that the squeezed-off part be
subsequently cut out and replaced.
Advice provided by Wavin, U.K. is that:
"On release of the squeeze, the pipe should be:
(a) Inspected and re-rounded if necessary.
(b) Renewed if there is any indication of damage (e.g. cracking or splitting).
(c) Adequately marked and recorded (e.g. marked "squeezed" at the point of
compression)".
These UK recommendations are for pipes up to and including 500 mm diameter i.e.
DN 500.
Freeze-off has been successfully applied in Australia especially with the smaller diameter
PE pipes commonly used in property service connections.
Freeze-off is not used in the U.K. Some objections from the U.K. to freezing are:
(i) The time taken due to the relatively poor thermal conductivity of PE cf. copper.
(ii) A health and safety issue concerning "working with your head in a pool of CO 2".
In Australia the freeze-off technique is not considered to be a problem, except that the
freezing time will obviously be longer than for metallic pipes. If there is a genuine OH&S
issue with the use of CO2 then it is indeed an issue that applies to all pipe materials that
employ this technique e.g. copper.
2.14.3.2 Recommended squeeze-off practice
Where PE pipelines are isolated in an emergency using the squeeze-off technique, only
specially designed squeeze-off tools shall be used to avoid over compression and
minimise damage. Since the pipe will always be damaged by squeeze-off, the damaged
area shall be cut out and replaced at the earliest practicable time.
Under no circumstances shall the PE pipe be bent backwards to stop the flow unless the
pipe is to be replaced back to at least 5 pipe diameters from point of isolation.
For squeeze-off up to and including DN 50, it is recommended that the U.K. approach be
adopted i.e. only cut out and replace in the event of visible damage, and mark the PE pipe
as squeezed using a suitable marker tape.
COPYRIGHT
WSA 01—2004-3.1 32
Alternatively, freezing may be used using the standard equipment that is currently used for
copper pipe.
2.15 ELECTRICAL SAFETY

PE pipe is a poor conductor of electricity. In the majority of older properties in Australia, a
buried metallic water service pipe is used either as the main earth or is bonded to the
earthing system. If this earthing arrangement is destroyed or modified, it may create an
electrical hazard under some conditions.
To avoid creating an electrical hazard, precautions need to be taken where metallic water
services (and in some cases the water main), which form part of the property electrical
earthing systems, are replaced with PE pipe.
Wherever metallic pipe systems are replaced with PE pipe, the property electrical earthing
system shall be checked and where necessary made safe by a licensed electrical
contractor.
COPYRIGHT
33 WSA 01—2004-3.1
3 NON-PRESSURE PIPELINES
3.1 GENERAL
PE pipes and fittings for gravity sewers, drains and other non-pressure pipelines shall
comply with AS/NZS 5065. PE maintenance shafts shall comply with AS/NZS 4798.
Requirements for other PE products used in non-pressure pipelines and additional
requirements for non-pressure pipelines are set out below.
3.2 COMPOUND DESIGNATION

Compounds that comply with AS/NZS 4131 (Refer to PIPA Guideline POP004 for a list of
complying compounds) or the compounds specified in the relevant product standard shall
be used.
3.3 PIPELINE SIZES

For sewers, sizes DN 110, 125, 160, 180, 280, 355, 450 and larger sizes as listed in the
relevant product standard (refer to Clause 3.1) shall be adopted unless otherwise specified
(Refer to manufacturers for available pipe sizes).
3.4 STIFFNESS [SN]

Unless otherwise specified, minimum stiffness class of sewers shall be SN 8.
For other applications, stiffness classes shall be determined in accordance with
AS/NZS 2566.1.
3.5 COLOUR
Buried pipe for gravity sewerage applications shall be black or black with a co-extruded
internal white or natural liner so as to permit accurate inspection and coding of the sewer
condition using CCTV equipment. Buried fittings shall be black.
The contents of above ground pipelines shall be identified in accordance with AS 1345.
3.6 STORAGE
Pipe and fittings shall be stored as follows:
(a) All pipe shall be stacked in a manner to minimise pipe ovalisation.
(b) Fittings and sealing materials shall be left in the original sealed cartons until used
and stored in secure areas away from direct sunlight.
For solid black pipe, fittings and fabrications outside storage can be unlimited.
Large diameter pipes and fabrications, such as maintenance shafts, may require special
provision to preserve dimensional properties.
3.7 STANDARD LENGTH

Unless otherwise specified, the industry standard lengths for gravity sewers shall be
nominal 12 m.
Other lengths (6, 15 and 20 m) may also be supplied to order. Designers should check with
manufacturers for their nominated standard lengths and that longer lengths are
transportable to site and able to be handled on site.
COPYRIGHT
WSA 01—2004-3.1 34
Coiled PE pipe when removed from the coil or drum will be oval and curved. The extent of
ovality and curvature will depend upon the ambient temperature, SDR, pipe diameter, coil
diameter and compound type. Coiled pipe is usually limited to a maximum of DN 125.
The use of coiled pipe is also limited by the requirement to lay gravity sewers on grade
within specified construction tolerances (Refer to WSA 02). Where both ovality and
curvature can be reduced to an acceptable level by suitable coil handling and levelling
equipment to facilitate handling, jointing and laying on grade, then coiled pipe may be
suitable for gravity sewer installations.
3.8 FITTINGS
PE Fittings for non-pressure sewers shall:
(a) be preferably fully moulded;
(b) comply with AS/NZS 5065; and
(c) be SDR 33 or thicker for MH drop assemblies and for above-ground applications.
Bends formed from pipe, shall have a minimum wall thickness not less than the pipe to
which they are to be connected.
Depending on the forming process and the amount of wall thinning produced, the pipe
used to forms bends may need to be thicker (lesser SDR) than the pipe to which it is to be
connected.
3.9 PIPELINE DESIGN

3.9.1 System Life
The life of non-pressure PE pipelines will be dependent on performance under four main
conditions:
(a) Soil mechanics and pipe mechanics stability.
(b) Pipe material strength.
(c) Chemical and biological stability.
(d) Functional stability.
The life of thermoplastic non-pressure pipeline systems has been extensively studied and
reported. For example, the report titled "Plastics Pipes—How Long Can They Last", by
Prof. Lars-Eric Janson of VBB Sweco Consulting Group reaffirmed a 1987 report
concluding that the answer to the above question was "at least 100 years". The latest
report, produced in 1996, states that "...it has been clearly found that nothing has
emerged, which contradicts the statement made in 1987." It also states that the report
refers mainly to buried gravity sewer pipes, but the conclusions can in most cases be
applied for pressure applications. The aim of the work was to verify the claim of "at least
100 years".
The summary states that "…one can thus conclude that everything is pointing to at least
100 years practical service life for today's buried sewer pipes made of high quality virgin
PVC-U and PE resins, on condition that the pipes are used in accordance with the
prevalent national standard installation instructions."
Provided that PE pipeline system components are appraised and supplied to nominated
industry standards under third-party product certification systems, and provided pipelines
are designed and constructed correctly, then the likelihood of failure is minimised. For
correctly manufactured and installed systems, the actual life can not be predicted, but can
logically be expected to be well in excess of 100 years before major rehabilitation is
required.
COPYRIGHT
35 WSA 01—2004-3.1
If a system life is to be assigned beyond 100 years, it shall be based on the likelihood of
failure arising from the above factors.
3.9.2 Structural
Pipeline structural design shall comply with AS/NZS 2566.1.
3.9.3 Hydraulic
Pipeline hydraulic design shall comply with WSA 02 or as nominated by the Water Agency.
3.9.4 Environment
Where the pipeline is to be installed in suspected contaminated ground, specific soil
sampling shall be undertaken to identify reagents in the ground and surrounding
groundwaters. Contaminated soils deemed to be damaging to PE (Refer to Clause 2.10.5)
shall be removed from site. Where leaching of contaminants into the pipe alignment may
re-occur the PE pipe shall be contained in an impervious sealed conduit.
The properties of PE make such pipelines particularly suitable for areas subject to ground
movement due to expansive clays, seismic forces, mining subsidence or compaction of
filled sites. In addition fusion jointed PE pipelines provide a high degree of confidence in
pipeline integrity and therefore suitability for installation in areas of environmental
sensitivity where exfiltration cannot be tolerated.
The information in AS 2033 Appendix A relates to constant exposure to the chemicals
concerned. Ground contaminants are often only present in small quantities or
concentrations. In these circumstances, the advice of the manufacturer should be sought.
3.10 INSTALLATION
3.10.1 Trenching and embedment
Trenching and embedment shall be in accordance with:
(a) firstly the Design Drawings;
(b) secondly WSA 02 and the Standard Drawings included therein; and
(c) thirdly AS/NZS 2566.2.
For additional information refer to the Standard Drawings in Appendix C and WSA 02.
3.10.2 Pipelaying
Pipelaying shall be in accordance with WSA 02 and the following requirements:
(a) PE pipes shall be installed to allow for the difference in ambient temperature and the
in-ground temperature.
(b) PE pipes shall be laid in the trench to line and level with full embedment and partial
trench backfill without restricting the ends until the pipe has had time to stabilise to
ground temperature.
(c) Installations using directional drilling or similar processes should be considered on
their merits with respect to grade, alignment, ground conditions, obstructions and
environmental considerations.
3.10.3 Property connection sewers and maintenance shafts
PE property connection sewers (also known as property branches or sidelines) shall be
constructed in accordance WSA 02 and the Water Agency’s requirements. Property
connection sewers constructed from PVC shall have a junction fitting included in the
reticulation sewer and the conversion from PE to PVC shall be adjacent to this junction.
Conversion from PE to PVC shall be by means of metal-banded flexible coupling with
shear band.
COPYRIGHT
WSA 01—2004-3.1 36
PE maintenance shafts (MS) shall be fusion jointed to the sewer.

3.10.4 Jointing
Butt welding or electrofusion jointing shall be used. Only trained and certified welders shall
perform weld jointing of pipelines. (refer to Section 5).
Removal of the internal weld bead in butt welded gravity sewers is not considered
necessary from hydraulic considerations, except in gravity sewers graded 1 in 40 or flatter
or where dry weather velocities do not exceed 0.3 m/s.
Connections to PVC/ABS/DI/steel pipelines shall be made using PE flange adaptors to
AS 4087 Figure B2 requirements using stainless steel backing plates and fasteners.
Connections to VC/GRP/RC pipelines shall be made using a spigot end adaptor welded to
the PE pipe spigot, and utilising the socket and sealing ring of the VC/GRP/RC pipe.
3.10.5 Maintenance holes and maintenance shafts
For connection of PE pipe to concrete MHs, use a one size larger diameter PVC
(AS/NZS 1260) sanded elastomeric seal joint coupling cast into the MH wall. A fabricated
thick wall section PE spigot fitting with outside diameter to match the coupling ID, butt
welded to the PE sewer pipe shall be inserted into the PVC socket accordingly. A puddle
flange and concrete anchor shall be used either side of the MH to maintain the pipe
location in the PVC socket.
Typical construction details for MH connections are shown in Standard Drawing SEW–
1317.
For PE MHs and MSs, butt welding or electrofusion jointing shall be used to seal the
entry/exit of PE sewers to the MH or MS.
For drop assemblies contained within the MH, the pipe and fittings shall be SDR 33 or
thicker. For guidance on restraining MH drop assemblies refer to Standard Drawing SEW–
1306.
3.11 WELD PRE-QUALIFICATION

3.11.1 Butt fusion
Refer to Clause 2.12.1.
3.11.2 Electrofusion
Refer to Clause 2.12.2.
3.12 TESTING
Non-pressure PE pipelines shall be tested for leakage using low pressure air testing or
hydrostatic testing in accordance with the procedures outlined in AS/NZS 2566.2. All
acceptance testing shall be performed after backfilling.
Where specified, non-pressure PE pipelines shall be deflection tested in accordance with
AS/NZS 2566.2. To allow for stabilization of the pipe soil system, deflection testing shall be
conducted at a specified period after installation nominated by the Water Agency. To
ensure accurate measurements the pipeline shall be cleaned before deflection testing.
The testing will detect damaged piping or improper jointing, but cannot be used as a
quantitative measure of leakage under service conditions for infiltration or exfiltration. A
standard test method for installation acceptance of plastic gravity sewer lines using low
pressure air is also published by ASTM, viz F1417. The time between the completion of the
backfill operation and testing may be specified by the Water Agency. The test may also be
COPYRIGHT
37 WSA 01—2004-3.1
used as a preliminary test that enables the installer to show the condition of a buried line
prior to the final backfill, paving and other construction activities.
The vertical deflection of the installed pipeline should be determined either by direct
measurement, or indirect measurement using devices such as electronic deflectometers
and calibrated television or video cameras. Pipelines jointed by butt welding may require
the internal weld beads removed, depending on the deflection testing method used.
Passing an internal proving plug through the pipeline is not recommended.
ASTM D2321 Standard Practice for Underground Installation of Thermoplastic Pipe for
Sewers and Other Gravity Flow Applications recommends that deflection tests should be
performed at least 30 days after installation, but advises, as a quality control measure, that
periodic checks of deflection be made during installation. ASTM F894 Standards
Specification for Polyethylene (PE) Large Diameter Profile Wall Sewer and Drain Pipe
recommends a maximum acceptance deflection of 7.5% at 30 days minimum.
3.13 MAINTENANCE
3.13.1 Post installation connections
Connections shall be made using either:
(a) slip type electrofusion couplings; or
(b) fabricated stainless steel spigot slope junctions complying with the performance
requirements of AS 4181; or
(c) electrofusion saddles.
3.13.2 Repairs
Repairs shall be undertaken using electrofusion slip couplings or stainless clamps
complying with AS 4181.
COPYRIGHT
WSA 01—2004-3.1 38
4 RELINING APPLICATIONS
4.1 GENERAL
A common relining technique for the rehabilitation of both pressure and a non-pressure
pipeline, which utilises the material characteristics of PE, is sliplining. This technique
consists of inserting a pre-welded length of PE pipe into the host pipe that requires
rehabilitation. The normal process uses pipe of full specification that can be regarded as
an independent pipe. This leaves an annular space between the new pipe and the old that
should be grouted. New variants include 'Rolldown', 'Swagelining', 'Fold and form', 'U-liner'
and 'Cold die drawn lining'. These methods eliminate the annulus, together with the need
for grouting, the new pipe having an interference fit with the old.
Pipe cracking or pipe bursting is an alternative to sliplining where size for size or larger
sizing is required. This involves breaking the existing pipeline, pushing the fragments into
the surrounding embedment, pulling through a new PE pipe. Pipes as large as or larger
than the original pipe can be used.
Dependent upon the criticality of the pipeline requiring rehabilitation, some pipe cracking or
pipe bursting installations may require the use of a sleeve pipe that is sliplined using a new
PE pipe.
Many of these techniques are specialised and registered or even patented systems, which
are beyond the scope of this Code.
4.2 MATERIALS
The requirements listed in Sections 2 and 3 of this Code shall apply for pressure and non-
pressure relining systems, respectively.
4.3 PIPE
Relining pipes shall comply with EN 13566-1, prEN 13566-2, EN 13566-3 and EN 13566-4
as appropriate to the relining technique being used and those listed below.
4.3.1 Nominal diameters
Pipe diameters shall be selected from the sizes listed in AS/NZS 4130 to provide the
closest fit inside the pipe or bore provided.
4.3.2 Length
For relining applications of pipe diameters up to DN 125, pipe coils shall be used.
For pipe diameters larger than DN 125, the pipe shall be in longest manageable straight
lengths.
4.3.3 Colour
Colour requirements for pressure (Clause 2.6) and non-pressure pipe (Clause 3.5) shall be
used for relining applications, where the host pipe does not remain intact eg, pipe cracking.
Gravity sewer relining applications shall be black with a co-extruded internal white or
natural liner.
4.4 FITTINGS
Fittings for relining applications shall follow those adopted for pressure and non-pressure
pipe systems in Sections 2 and 3 respectively.
COPYRIGHT
39 WSA 01—2004-3.1
4.5 PIPELINE DESIGN

Pipeline design for relining applications shall follow the principles adopted for pressure and
non-pressure pipe systems in Clauses 2.10 and 3.9 respectively.
4.6 INSTALLATION
4.6.1 General
Unless specified below the installation requirements specified in Clauses 2.11 and 3.10
shall apply.
For non-pressure applications, grouting shall be applied between the liner and existing
pipe where a gap exists.
Grout shall be applied around all branch junctions for non-pressure applications.
During installation of the PE pipe from the surface into the host pipe at the bottom of the
trench, suitable mechanical handling precautions shall be adopted to ensure that the
relining pipe is not damaged.
4.6.2 Jointing
For safety reasons all main pipe fusion processes shall take place above ground except in
circumstances where the contractor can demonstrate that it is not technically practicable.
For pipe up to DN 90, either compression fittings or electrofusion jointing shall be used
where space and installation conditions dictate.
For PE pipe above DN 90, butt weld jointing shall be used.
Elastomeric seal joints may be installed for non pressure PE sewers within contained
spaces where grouting is applied in the annulus between the pipe and the bore hole where
the rubber seal ring joint long term performance for contact pressure and width meets the
requirements of AS/NZS 1260.
4.6.3 Connections
Electrofusion couplings, electrofusion saddles or wrap around couplings shall be used
(refer to Clauses 2.11.5 and 3.10.3), except that for pressure mains up to and including
DN 63 bolt on bands with lip type seals may also be used.
Post installation connections shall have the joints made by digging down to the connection
point to install the connector.
For connection to an MH or MS refer to Clause 3.10.5 of this Code.
4.7 RELINING TYPES

4.7.1 Sliplining
For free inserted pipe, the insert pipe diameter may be up to 99% of the internal diameter
of the existing pipe.
As wall thicknesses of the host pipe are site specific, the external loads shall be evaluated
in accordance with AS/NZS 2566.1, and maximum deflection be limited to 7.5% for long
term and 4% for short term of the pipe outside diameter.
Where specified, non-pressure pipelines shall be grouted and the grout pressures limited
by external pressure capacity of pipe. A factor of safety of 2.0 against buckling shall be
adopted.
The bending radius of an inserted pipe shall be greater than 25 times the outside diameter
of the pipe.
COPYRIGHT
WSA 01—2004-3.1 40
For liner pipe pulled into existing cavities, the maximum end load shall be limited to that
causing a maximum allowable strain for the pipe material. Liner pipe shall be allowed to
relax after insertion for a period equal to the time of insertion loading.
Reference may be made to the POLIplex Polyethylene Pipe Design Text Book (published
by Iplex Pipelines Australia) in Section Seven (Table 7.6.5 on page 7-74) which sets out
safe axial tensile loads in PE pipes.
Where short length pipe sections are jacked into the existing line, the maximum jacking
loads shall be limited to the load capacity of the specific joint type. Unless otherwise
specified, a factor of safety of 2.0 shall be adopted.
The controlling design feature for jacking sections, is the compressive bearing capacity of
the joint section. Any particular joint design shall have load data prepared to establish
jacking load capacity without compression collapse.
4.7.2 Pipe cracking and moling
Where pipe cracking or moling is applied the PE pipe used shall be selected for normal
pressure or external load considerations.
4.7.3 Swagelining
Where swage, draw down or diameter reduction is used, the pipe shall be PE 80B or
PE 100 material.
The actual liner pipe diameters shall be established on a project by project basis as they
are site specific.
4.8 TESTING
The methods of testing specified for open trench installations shall be maintained for PE
relining both in pressure and non-pressure pipelines.
COPYRIGHT
41 WSA 01—2004-3.1
5 PERSONNEL QUALIFICATIONS
5.1 GENERAL
The handling, laying, jointing, trench filling and testing of all water mains, construction and
testing of associated structures and installation of appurtenances shall be carried out, and
supervised by, acceptably qualified and/or accredited personnel.
Personnel shall hold minimum qualifications or specialist accreditation appropriate for the
work undertaken.
Minimum qualifications shall mean Statements of Attainment for all those Units of
Competence, nominated by the Water Agency, from the Water Industry National Training
Package NWP2000 or Local Government Training Package LGA00 or the Civil
Construction Training Package BCC98 or other relevant Training or a combination of one
or more of the aforementioned.
Specialist accreditation shall mean a qualification achieved through specialised training
and assessment for a specific product and/or situation that is not covered by relevant
Training Packages.
Qualifications from Training Packages shall be awarded by a registered training
organisation.
Training and assessment for specialist accreditation shall be provided by registered
training organisations or recognised organisations with appropriately qualified and
experienced trainers and assessors.
Registered training organisations shall be those listed by the National Training Information
Service for the provision of training or assessment services as required.
Training packages, together with relevant short training courses and training/assessment
service providers are provided by the National Training Information Service at
www.ntis.gov.au/.
5.2 WELDING
The welding of components shall be carried out, and supervised by acceptable qualified
and/or accredited personnel, who have successfully undertaken the following Units of
Competence of the Plastics, Rubber and/or Cablemaking Training Package PMB01
appropriate to the welding processes used:
(a) PMBWELD301A—Butt weld polyethylene plastic pipelines
(b) PMBWELD302A—Electrofusion weld polyethylene pipelines
“Successfully undertaken” shall mean “Statement of Attainment” for all those appropriate
Units of Competence.
Only personnel who have successfully completed the above training programs shall be
permitted to work on PE systems.
Certification shall be valid for 2 years and be limited to the actual materials, sizes, and
equipment covered in the specific training program. At the end of this period, renewal of
the certification shall be required.
Certified welders shall demonstrate continuous welding activity and any break of more than
six months shall require renewal of certification.
Certification details shall be carried by field personnel on-site, and be made available as
required.
COPYRIGHT
WSA 01—2004-3.1 42
The training organisation shall maintain a database of course participants and their
certification status for access by contract principals as required for specific installation
projects.
5.3 TRENCHLESS TECHNOLOGY

The use of trenchless technology including relining applications outlined in Section 4 shall
be carried out, and supervised by acceptable qualified and/or accredited personnel, who
have successfully undertaken the following Units of Competence of the Civil Construction
Training Package BCC30903.
“Successfully undertaken” shall mean “Statement of Attainment” for all those appropriate
Units of Competence.
Only personnel who have successfully completed the above training programs shall be
permitted to work on PE systems.
Certification details shall be carried by field personnel on-site, and be made available as
required.
COPYRIGHT
43 WSA 01—2004-3.1
APPENDIX A
EQUIVALENT PIPE DIAMETERS
The following tables of equivalent pipe diameters have been produced to show the actual
mean internal diameters of the CICL and AC water mains, laid extensively in the post
World War II period to the mid 1970’s, compared to PE. Tables of equivalent pipe
diameters with CICL and AC pressure pipes have been prepared from the pipe dimensions
contained in Australian Standard Specification for Centrifugally Cast Iron Pressure Pipes
for Water, Gas and Sewage (AS A145—1965) and Australian Standard Specification for
Asbestos Cement Pressure Pipes and Joints (AS A41—1959). For CICL calculations,
nominal values have been used, while for AC calculations, the internal diameters specified
in the Standard were based upon minimum wall thicknesses. Class C CICL was most
commonly used by Water Boards at that time, while for AC pipe individual Water Agency
records should be consulted.
For pipe materials used since the late 1970’s consult current Australian Standards.
COPYRIGHT
WSA 01—2004-3.1 44
TABLE A1
TABLE OF EQUIVALENT PE PIPE DIAMETERS CICL
PRESSURE PIPE AS A145—1965
CICL PE
Size Class Mean ID* DN PN Compound Mean ID

in/DN in/mm mm
4/100 C 3.68/93 110 12.5 PE 80B 89
D 3.60/91 PE 100 93
16 PE 80B 84
PE 100 89
125 12.5 PE 80B 101
PE 100 106
16 PE 80B 96
PE 100 101
6/150 C 5.74/146 160 12.5 PE 80B 130
D 5.62/143 PE 100 136
16 PE 80B 123
PE 100 130
180 12.5 PE 80B 146
PE 100 153
16 PE 80B 138
PE 100 146
8/200 C 7.63/194 250 12.5 PE 80B 203
D 7.51/191 PE 100 212
16 PE 80B 192
PE 100 203
9/225 C 8.55/217 280 12.5 PE 80B 228
D 8.41/214 PE 100 238
16 PE 80B 215
PE 100 228
10/250 C 9.57/243 315 12.5 PE 80B 256
D 9.41/239 PE 100 268
16 PE 80B 242
PE 100 256
(continued)
COPYRIGHT
45 WSA 01—2004-3.1
CICL PE
Size Class Mean ID* DN PN Compound Mean ID

in/DN in/mm mm
12/300 C 11.35/288 355 12.5 PE 80B 289
D 11.19/284 PE 100 302
16 PE 80B 273
PE 100 289
15/375 C 14.62/371 450 PE 80B 366
D 14.44/367 PE 100 382
PE 80B 346
PE 100 366
* Heavy lining thickness values applied.

NOTE:
Closest equivalent PE pipe size and compound combinations to match the CICL mean internal diameters can
be determined by comparing mean internal diameters.
COPYRIGHT
WSA 01—2004-3.1 46
TABLE A2
TABLE OF EQUIVALENT PE PIPE DIAMETERS AC PRESSURE PIPE
AS A41—1959
AC PE
DN Class* Mean ID DN PN Compound Mean ID

mm mm
100 B 101 125 12.5 PE 80B 101
C 97 PE 100 106
16 PE 80B 96
PE 100 101
150 B 155 180 12.5 PE 80B 146
C 146 PE 100 153
16 PE 80B 138
PE100 146
200 B 203 250 12.5 PE 80B 203
C 196 PE 100 212
16 PE 80B 192
PE 100 203
225 B 229 280 12.5 PE 80B 228
C 219 PE 100 238
16 PE 80B 215
PE 100 228
250 B 253 315 12.5 PE 80B 256
C 243 PE 100 268
16 PE 80B 242
PE 100 256
300 B 299 355 12.5 PE 80B 289
C 295 PE 100 302
355 16 PE 80B 273
PE 100 289
375 B 370 450 12.5 PE 80B 366
C 363 PE 100 382
16 PE 80B 346
PE 100 366
* Class B = 122 m head Class C = 183 m head

NOTE:
Closest equivalent PE pipe size and compound combinations to match the AC mean internal diameters can be
determined by comparing mean internal diameters.
COPYRIGHT
47 WSA 01—2004-3.1
APPENDIX B
REFERENCES FOR USE BY DESIGNERS WHEN MANAGING THE RISK OF
INSTALLATION, OPERATION AND MAINTENANCE OF PE PIPELINE SYSTEMS IN
CONTAMINATED LAND
Laying Potable Water Pipelines in Contaminated Ground—Guidance Notes Report FR
0448 Nov 1994 Foundation for Water Research.
BSI (1988) Draft for Development Code of Practice for the Identification of Potentially
Contaminated Land and its Investigation, DD 175:1988.
Construction Industry Research and Information Association, (1993) Guide to Safe
Working Practices for contaminated Sites, CIRIA, London.
Protection of Workers and the General Public during Development of Contaminated Land
(1991) Health and Safety Executive, HMSO, London.
Arnaout S and Peck R R (1988) Pipe Line Installation in Contaminated Land WRc Report
ER 319E.
Wilson I and Norris M (1992) Effects of Organic Chemicals in Contaminated Land on
Buried Services, WRc report for the Department of the Environment DoE 2982-(P).
Contaminated sites: legal and financial responsibility, and planning solutions/report
prepared by national Capital Planning Authority for Better Cities Program AGPS 1993.
COPYRIGHT
WSA 01—2004-3.1 48
APPENDIX C
STANDARD DRAWINGS
C1 GENERAL
Standard Drawings that support Polyethylene Pipeline Code are included to assist
understanding of the principles and methodology involved in construction of PE pipeline
systems and to enhance the design and construction requirements of this Code and should
be read in conjunction with them.
The Standard Drawings provide a “Deemed to Comply” solution for the installation of
particular elements of a water supply or sewerage system that are specific to PE. Standard
Drawings of other WSAA Codes should also be referenced as appropriate. However, the
Drawings will not suit all circumstances or overcome all problems. To meet special needs,
Designers and Constructors are encouraged to identify improved construction methods and
other variations from the requirements set out in the drawings. Approval from local Water
Agencies will be necessary before any major departures from the principles outlined in the
drawings are implemented. Successful initiatives will be considered by WSAA for inclusion
in future editions of this Code.
All Design Drawings should include the name of the Water Agency and have a signature
block to allow confirmation that each drawing complies with Water Agency requirements.
The symbols and markings used on these Drawings are typical only and do not apply to
any particular Water Agency (Refer to the individual Water Agency for their legend, symbol
and layout requirements).
Individual Water Agencies may have specific information and presentation requirements,
which should be determined before commencing any project. Any additional information,
layout or format requirements specified by the Water Agency take precedence over these
Drawings.
All special requirements including, but not limited to geotechnical requirements,
embedment and compaction details, should be shown in the Design Drawings and/or the
Specification.
COPYRIGHT
49 WSA 01—2004-3.1
C2 LISTING OF STANDARD DRAWINGS

Equivalent
DRAWING 1999
ACTIVITY TITLE
NUMBER DRAWING
NUMBER
PIPELINE LAYOUT
WAT–1102 Typical Mains Construction Reticulation Main Arrangements WAT–200
WAT–201
WAT–1104 Typical Mains Construction DN 63 PE Cul-de-Sac Arrangement WAT–202
WAT–1105 Typical Mains Construction Connection to Existing Mains
EMBEDMENT / TRENCHFILL AND RESTRAINTS
WAT–1201 Embedment & Trenchfill Typical Arrangement WAT–100
WAT–1211 Buried Crossings Under Obstructions WAT–105
INSTALLATION PRACTICES/ STRUCTURES
WAT–1313 Flanged Joints Bolting Details
FABRICATION DETAILS
WAT–1409 Hydrant Installation Fittings PE Assemblies PE–14
ACCESS STRUCTURES
SEW–1306 Maintenance Holes Alternative Drop Connections SEW–206

SEW–1317 Maintenance Holes Typical MS Cover Arrangements SEW–212
COPYRIGHT

WSA01 2004 3 1 Pipeline PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

WSA01 2004 3 1 Pipeline PDF

Uploaded by

Copyright:

Available Formats

WATER SERVICES ASSOCIATION

Polyethylene Pipeline Code

Originated as WSA 01—1998

Previous edition WSA 01—2001

2.11.4 Pipeline anchorage ..................................................................................... 25

4.4 FITTINGS ............................................................................................................. 38

5 PERSONNEL QUALIFICATIONS ............................................................................ 41

Section 3 NON-PRESSURE PIPELINES

1.4 REFERENCED DOCUMENTS

1.5 FURTHER READING

GRP glass reinforced polyester

2.2 COMPOUND DESIGNATION

2.3 PIPE SIZES

2.4 EQUIVALENT PIPE SIZES

2.5 PRESSURE CLASS

2.6 PIPELINE IDENTIFICATION

2.6.6 Surface fittings

2.8 DELIVERY INSPECTION

2.9 STANDARD LENGTHS

(b) For straight lengths, nominal 12 m.

2.10 PIPELINE DESIGN

2.10.4 Fitting design factors

2.10.5 Pressure pipe design factors

Condition Installation Factor Index

2.10.8 Surface obstructions and clearances

Pipe diameter Clearance to wall or building

2.10.9 Underground obstructions and services and clearances

(a) tapping PE minor mains (<DN 63);

2.12 WELD PRE-QUALIFICATION

2.13 TESTING AND COMMISSIONING

2.13.2 Pre-Testing Procedures

2.13.5.3 Test procedure

2.15 ELECTRICAL SAFETY

3.2 COMPOUND DESIGNATION

3.3 PIPELINE SIZES

3.4 STIFFNESS [SN]

3.7 STANDARD LENGTH

3.9 PIPELINE DESIGN

PE maintenance shafts (MS) shall be fusion jointed to the sewer.

3.11 WELD PRE-QUALIFICATION

4.5 PIPELINE DESIGN

4.7 RELINING TYPES

5.3 TRENCHLESS TECHNOLOGY

Size Class Mean ID* DN PN Compound Mean ID

4/100 C 3.68/93 110 12.5 PE 80B 89

125 12.5 PE 80B 101

6/150 C 5.74/146 160 12.5 PE 80B 130

D 5.62/143 PE 100 136

180 12.5 PE 80B 146

8/200 C 7.63/194 250 12.5 PE 80B 203

D 7.51/191 PE 100 212

9/225 C 8.55/217 280 12.5 PE 80B 228

D 8.41/214 PE 100 238

10/250 C 9.57/243 315 12.5 PE 80B 256

D 9.41/239 PE 100 268

Size Class Mean ID* DN PN Compound Mean ID

12/300 C 11.35/288 355 12.5 PE 80B 289

D 11.19/284 PE 100 302

15/375 C 14.62/371 450 PE 80B 366

D 14.44/367 PE 100 382

* Heavy lining thickness values applied.

DN Class* Mean ID DN PN Compound Mean ID

100 B 101 125 12.5 PE 80B 101