Test procedures for pressure and gravity

pipes maintenance structures

This technical guideline is provided to Power and Water Accredited Certifiers (certifying consultant) undertaking testing of
newly constructed water and sewer assets.
Power and Water personnel must be notified a minimum of two working days prior to any testing of mains.
Note that only authorised Power and Water personnel and authorised Power and Water contractors are permitted to
undertake works on existing live assets including physical access. At no stage must any other persons carry out work on
Power and Water infrastructure.

Pressure mains (water or sewer) and services equal to or greater than 100mm
Hydrostatic test all pressure mains after trench filling and compaction and after all thrust restraining concrete have cured
for at least three days. For large land subdivision developments, all lot connections must be included in the test. Water
for testing must be clean, potable quality water, obtained from the existing mains supply.
The pressure test must be a minimum of 1050 kPa for mains up to DN300. Mains equal or greater than DN375 must be a
minimum of 1200 kPa. Loss of pressure greater than 50 kPa results in failure of test. Shorten the length of pipeline to test
where practical or if significant changes in elevation affect test pressure.
Adopt a maximum test length of 1000 m. If practically beneficial, the certifying consultant can test the mains in sections.
A water and sewer infrastructure plan to track sections of mains tested is recommended. Pressure and chlorination
testing can be combined to reduce time taken for commissioning.
The contractor is permitted to hydrostatically test against existing valves after the valve is closed and locked by Power
and Water personnel. Power and Water cannot guarantee the condition of existing valves and that they will hold pressure
during test.
A blanking plate or spade between flanges is also acceptable, provided that there is adequate lateral restraint in the
immediate area to prevent dislodging of socketed pipe fittings. Based on site conditions, the spade specification
(thickness and material) must be provided by the certifying consultant
Where no valve exists or at an end cap, Power and Water may install a valve with a puddle flange thrust block at the
developer’s expense to provide isolation between new and existing mains.
Pressure testing polyethylene (PE) pipes requires special processes as 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 behaviour, standard pipe testing
may not be suitable for PE pipes. Testing of PE mains and services must be tested separately from all other pressure
mains of different material and as per WSA 01-2004 Polyethylene Pipeline Code Version 3.1.

Test procedure
1. Prior to setting test pressure, allow a minimum of 24 hours for the test water temperature to stabilise and
dissolved air to vent from the system. Fill cement-lined pipes 24 hours prior to testing to allow for lining
saturation. Clean the section and then slowly fill it with water, ensuring that air has been completely expelled.
2. Use a test rig that has two calibrated pressure gauges. Each gauge must have a range of 0 – 2500 kPa and must
have a current calibration certificate within six months of test date. Both gauges must read within 5% of each
other. Use the gauge recording the lower of the two readings.
3. Pressurise the line to 75% of the test pressure and leave for a minimum of 12 hours. The preliminary
pressurisation is intended to:
a. stabilise the main by allowing most of the time-dependent movement to occur
b. achieve saturation in absorbent materials; and
c. allow pressure-dependent increase in volume of flexible pipes prior to the main test.

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 4. Provided there are no obvious leaks in the main, steadily raise the pressure in the main until the specified test
pressure is reached. Maintain the test pressure for four hours. Measure and record the pressure reading at half
hour intervals. Visually inspect the line for leaks. Loss of pressure greater than 50 kPa results in failure of test. If a
leak is suspected but is not visible, the certifying consultant can consider the use electronic assistance.

5. Accept the pressure test on a section of main if:

a. there is no failure of any thrust block, anchor block, pipe, fitting, valve, joint or any other pipeline
component
b. there is no visible leakage
c. the measured loss rate for the relevant test period of the pressure testing does not exceed the maximum
allowable loss rate as determined above.
6. If any of the tests prove to be unsatisfactory, detect and rectify the fault and re-test. Continue to rectify and re-
test until a satisfactory test result is achieved. Even if testing produces satisfactory results, rectify any main or
conduit in which there is a visible or detectable leak or blockage.
7. Flush and dispose of test water in accordance with the certifying consultant’s recommendation.

Water services up to 50mm

Test procedure
1. Test to 1050 kPa of pressure after physical completion of new water service.
2. A satisfactory test is where there is no drop in pressure or loss of water after minimum 30 minutes.
3. If required, locate and repair all leaks and retest in accordance with the procedures of this clause.

Welded joints for steel pipes

Test procedure
1. Air test each welded joint at 70kPa with the certifying consultant and Power and Water representative present,
as soon as possible after completion of the joint with dry air and before backfilling.
2. Apply a soapy water solution to the joint welds and inspect visually for leaks. Repair faulty weld and retest to
satisfaction of the certifying consultant.
3. Pressurise overlapped area between welds using the tapped hole provided.
4. On satisfactory completion of the test, seal the tapped hole by seal welding and grinding flush or sealing with a
hexagonal head plug and approved jointing compound.

Sewer maintenance hole (MH)

Vacuum air test of sewer MH as per test procedure below is Power and Water’s preferred test method. Test all MHs after
the backfill is placed and compacted.
Where the certifying consultant permits hydrostatic testing as an alternative to vacuum testing, the hydrostatic testing of
all MHs must be carried in accordance with the following requirements below.
All MHs must be tested.

Test procedure – vacuum air test

1. Apply an initial test vacuum pressure (negative pressure) of approximately 37 kPa to the top of the MH. Close the
valve on the vacuum line and shut off the vacuum pump. Allow the air pressure to stabilise for at least three
minutes to identify any initial leakage.
2. When the pressure has stabilised, allow the gauge pressure to drop and commence time recording when
pressure reaches 34 kPa. Record the time for the pressure to drop to 30 kPa.
3. Accept the MH under test if the time for the vacuum reading to drop from 34 kPa to 30 kPa meets or exceeds the
relevant time in the table below.
4. If the time is less than the minimum specified the table below, re-apply the vacuum to identify any leaks. Rectify
all defects prior to conducting any further testing. Rectify any visible or audible faults even if the vacuum testing
is satisfactory.

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VACUUM TEST - MINIMUM TIME INTERVALS FOR PRESSURE DROP
Depth (metres) Maintenance hole diameter
DN1200 DN1500 DN1800
Time (Seconds)
≤ 2.4 20 26 33
3.0 25 33 41
3.7 30 39 49
4.3 35 46 57
4.9 40 52 65
5.5 45 59 73
6.1 50 65 81
6.7 55 72 89
7.3 59 78 97
7.9 64 85 105
8.5 69 91 113
9.1 74 98 121
NOTE: Times of intermediate diameters and depths may be interpolated

Test procedure – hydrostatic test

1. Hydrostatic testing of MHs will be undertaken by plugging all pipe openings in the walls and by filling the MHs with
water to the top of the access cover surround. The plugs must be positioned in the pipes as near as practicable to
the internal face of the maintenance structure.
2. After allowing a minimum of 30 minutes for absorption, the MH must be refilled and the loss of water during the
following 30 minutes measured.
3. The test on the MH will be considered satisfactory provided that there is no visible water loss. The plug of the
outlet must be fitted with a suitable release for emptying the MH on satisfactory completion of the test.

Sewer gravity mains

Sewer gravity mains can be either air (low pressure or vacuum) or hydrostatically tested as per the test procedures below.
The certifying consultant must determine the preferred method of testing.
The sewer gravity mains must be tested after the entire area with all other services is installed, and has been completed
to finished surface. It is recommended that large sewer mains (≥ DN750) be inspected and tested during construction and
before the construction of MHs.
All new sewer pipelines and sanitary drainage and other non-pressure installations must be tested. The tests are to
include external drops, property connections, vertical risers, inspection fittings and maintenance shafts.
The tests must also be applied to any section of existing pipeline or drain that has been repaired or replaced. Complete all
pipework including house drain connections and seal open ends (permanently where specified) before commencing test.
Plug pipeline ends tightly and leave joints exposed.

Test procedure – low pressure air test

1. Plug all sewer inlets and outlets and cap and seal all maintenance shafts, inspection opening shafts and risers in
the test length of sewer. Extra care must be considered as movement in the rubber ring joints on risers may occur.
2. Slowly apply an initial test pressure of approximately 27 kPa. Rapid pressurisation can cause significant air
temperature changes that may affect testing accuracy. Close the valve on the air pressure line and shut off the
pump. Allow the air pressure to stabilise for at least three minutes to identify any initial leakage.
3. When the pressure has stabilised, allow the gauge pressure to drop and commence time recording when pressure
reaches 24 kPa. Record the time over the test period specified in the table below.

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 4. Accept the length of sewer under test if the test pressure loss is less than 7 kPa for the relevant time interval
specified in the table below.
5. If the sewer fails the test, re-apply the pressure to identify any leaks. Rectify all defects prior to conducting any
further testing. Rectify any visible or audible faults even if the pressure testing is satisfactory.

Test procedure – vacuum air test

1. Plug all sewer inlets and outlets and cap and seal all maintenance shafts, inspection opening shafts and risers in
the test length of sewer.
2. Apply an initial test vacuum pressure (negative pressure) of approximately 27 kPa. Close the valve on the vacuum
line and shut off the vacuum pump. Allow the air pressure to stabilise for at least three minutes to identify any
initial leakage.
3. When the pressure has stabilised, allow the gauge pressure to drop and commence time recording when pressure
reaches 24 kPa. Record the time over the test period specified in the table below.
4. Accept the length of sewer under test if the test vacuum loss is less than 7 kPa for the relevant time interval
specified in the table below.
5. If the sewer fails the test, re-apply the vacuum to identify any leaks. Rectify all defects prior to conducting any
further testing. Rectify any visible or audible faults even if the vacuum testing is satisfactory.

AIR (LOW PRESSURE OR VACUUM) TEST – ACCEPTANCE TIMES FOR 7 KPA PRESSURE CHANGE
Pipe size DN Test lengths (metres)
50 100 150 200 250 300
Minimum test duration (minutes)
150 3 3 3 5 6 6
225 4 5 8 10 13 15
300 6 9 14 18 23 29
375 7 14 22 29 36 43
450 10 21 31 41 52 66
525 14 28 42 56 70 86
600 18 37 55 73 92 106
675 23 46 70 93 116 144
750 29 57 86 115 143 168
900 41 83 124 165 207 243
1000 51 102 153 204 255 300
1050 56 112 169 225 281 319
1200 73 147 220 294 367 460
1500 115 230 344 459 574 700
NOTES: Timing of the test duration to commence after the three minute initial period.
Test duration times for other combinations of pipe size and test length to be interpolated.

Test procedure – hydrostatic test

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 1. Fill the pipeline section with water and apply a test pressure head:
a. not less than two metres above pipe obvert or ground water level at the upstream end
b. not greater than six meters above pipe obvert at the downstream end.
2. Where the pipeline gradient of the test length is too steep to achieve the pressure head requirements, shorten the
pipeline test length.
3. Fill the pipeline slowly to the required head and bleed air from behind upstream plugs. For vitrified clay (VC) and
reinforced concrete (RC) pipes and cement mortar lined pipe, let the pipeline stand for at least two hours to
saturate the pipe walls.
4. Mark water level at the start of the test.
5. During pressuring, check for leakage from plugs and any test apparatus. Where leakage occurs, release the water,
make the necessary repairs and adjustments and re-fill.
6. Read just to the test pressure head and commence monitoring the loss of water for a test period of 30 minutes.
7. The test is not accepted if there is loss of water.
8. Re-apply the test pressure head and check the pipeline for leaks. Repair leaks to the satisfaction of the certifying
consultant and retest.

Spark testing of lined sewer maintenance hole (MH)

Visually inspect all plastics-lined concrete MHs for defects such as cuts, tears, or cracks and open or incompletely fused
thermoplastic lining welds.
Reject linings with visible projections or depressions that exceed 25 mm depth measured perpendicularly to the plastics
lined surface.
Probe all field welds of thermoplastic lining with a feeler gauge to determine all defective welds requiring re-welding i.e.
weak welds and welds where the probe enters more than 3 mm.
Mark all defects with chalk or a spirit pen with colour contrasting with the coating or lining.
Repair all visible and weld defects in accordance with the manufacturer’s printed instructions using qualified welders and
authorised methods.
After repair or visible and weld defects, undertake spark testing to detect discontinuities in accordance with Clause 7 of
AS 3894.1. Use equipment calibrated to 20,000 V within the last 12 months in accordance with Appendix C of AS 3894.1.

Test procedure
1. Allow 20 minutes inclusive of warm-up for the spark testing equipment to reach equilibrium conditions. Ensure the
surface of the lining is dry. Adjust the voltage of the spark testing equipment to a minimum of 12,000 V (but no
more than 13,000 V) and secure an earth connection to the underlying substrate.
2. Pass the brush electrode of the spark testing equipment over the lining at a rate of not greater than 0.3 m/s,
maintaining contact between the electrode and the test area and using an appropriate motion.
3. Where the instrument indicates a discontinuity, determine the exact location of the discontinuity (do not hold
electrode stationary against the surface) and clearly identify it on the test surface with the marker.
4. Continue testing until the entire coating or lining has been tested.
5. Undertake repair of discontinuities in accordance with the manufacturer’s printed procedures. Repeat spark
testing and repair cycle until there are no discontinuities detected.
6. If overheating during repairs causes any charring of thermoplastic welds, replace all charred sections in accordance
with the manufacturer’s printed procedures.

For more information:

Visit powerwater.com.au
Email waterdevelopment@powerwater.com.au
Phone 1800 245 092

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