Construction of Pipelines, Tunnels and Ancillary Work

SECTION 5
CONSTRUCTION OF PIPELINES, TUNNELS AND ANCILLARY WORK
5.1 GENERAL
1. Pipelaying shall conform to the procedures given in the following AWWA Standards and
Manuals and as modified in the Contract Specific Documents:
a) Cast Iron and Ductile Iron Pipe - Standard C600

b) Polyvinyl Chloride (PVC) Pipe - Manual M23
c) Steel Pipe - Manual M11
d) Concrete Pressure Pipe - Manual M9
e) Fiberglass Pressure Pipe - ASTM D3839
f) Polyethylene Pipe (Pe) - ASTM D2774
2. Where socketed pipes are required to be laid on a granular or sand bed, or directly on a
trench bottom, joint holes shall be formed in the bedding material or excavated Final Surface
to ensure that each pipe is uniformly supported throughout the length of its barrel and to
enable the joint to be made.
3. Pipes shall be laid on setting blocks only where a concrete bed or cradle is used.
4. Where pipes are required to be bedded directly on the trench bottom, the Final Surface shall
be trimmed and leveled to provide an even bedding to the pipeline and shall be free from all
extraneous matter that may damage the pipe, pipe coating, or sleeving.
5. No protective cap, disc or other appliance on the end of a pipe or fitting shall be removed
permanently until the pipe or fitting which it protects is about to be jointed. Pipes and fittings,
including any lining or sheathing, shall be examined for damage and the joint surface and
components shall be cleaned immediately before laying.
6. Suitable measures shall be taken to prevent soil or other material from entering pipes, and to
anchor each pipe to prevent flotation or other movement before the Work are completed.
7. Where pipeline marker tape is specified, it shall be laid between 150mm and 300mm above
the pipe. Where a tracer system is specified it shall be continuous and adequately secured to
valves and fittings.
8. Over-excavation shall be backfilled with material shown on the drawing or approved by MWC.
9. Final manufacture of special or cut pipes shall not be undertaken until actual on-site
dimensions have been determined.
10. Polyethylene pipes shall be snaked horizontally in the trench and shall be allowed to come to
equilibrium temperature with the trench before final backfilling and connections are made.
11. Unless otherwise detailed in the Bid Documents, the Contractor shall submit details of its
proposed method of crossing rivers and esteros. Preliminary details should have been
submitted with the Bid.
MWC Standard Engineering Section 05 Construction of pipelines, Version 01

Specifications Tunnels and Ancillary Works
Waste Water Page 1 of 26 Date: October 2009

5.2 PIPE BEDDING
1. Bedding for pipes shall be constructed by spreading and compacting the required bedding
material over the full width of the pipe trench. After the pipes have been laid, additional
material shall, if required, be placed and compacted equally on each side of the pipes, and
where practicable, this shall be done in sequence with the removal of the trench supports.
5.3 CONCRETE PROTECTION TO PIPES
1. Pipes to be bedded on or cradled with concrete shall be supported on pre-cast concrete

setting blocks, the top face of each block being covered with two layers of compressible
packing.
2. Concrete, provided as a protection to pipes shall be Class B (17 MPa), minimum 150 mm
thick, placed to the required depth in one operation.
3. Where pipes with flexible joints are used, concrete protection shall be interrupted over its full
cross-section at each pipe joint by shaped compressible filler.
4. Rapid hardening cement shall not be used in concrete for the protection of plastic pipe.
5. Plastic pipes shall be wrapped with a layer of plastic sheeting before being surrounded by
concrete.
5.4 COMPLETION OF PIPE SURROUND
1. After completion of the relevant operations in Clause 5.1, 5..2 and 5.3, fill material shall,
where required, be placed and compacted over the full width of the trench in layers not
exceeding 150 mm before compaction, to a finished thickness of 150 mm above the crown of
the pipes.
2. Subsequent filling shall then be carried out as specified in Sub-clause 2 of Clause 5.6.
5.5 PIPELAYING IN HEADINGS
1. Pipes to be laid in headings shall be supplied in lengths suitable for handling, jointing and
packing within the working space available.
2. Headings shall be driven from shaft to shaft or in such other lengths as may be described in
the Contract before any pipelaying is commenced.
3. After pipelaying, headings shall be packed solid with 17 MPa concrete so as to fill all voids.
Where manual packing is employed, each pipe shall be surrounded before laying and jointing
the next pipe.
4. When grouting of headings is described in the Contract, grouting pipes shall be left in the top
of the heading projecting behind each head tree and the whole grouted solid with grout.
Grouting shall be carried out at the end of each shift or after three settings have been
packed; whichever is the shorter interval.


5.6 THRUST BLOCKS
1. Except where welded steel pipelines or self-anchoring joints are used, thrusts from bends
and branches in pressure pipelines shall be resisted by concrete thrust blocks cast in contact
with undisturbed ground.
2. Any additional excavation required to accommodate thrust blocks shall be carried out after
the bend or branch is in position and the thrust face shall be trimmed back to remove all
loose or weathered material immediately prior to concreting.
3. Thrust blocks shall be allowed to develop adequate strength before any internal pressure is
applied to the pipeline.
4. Rapid hardening cement shall not be used in concrete for thrust blocks to plastic pipes.
5. Plastic pipes shall be wrapped with a layer of plastic sheeting before being surrounded by
concrete.
5.7 PIPE JOINTING GENERALLY
1. Pipe jointing surfaces and components shall be kept clean and free from extraneous matter
until the joints have been made or assembled. Care shall be taken to ensure that there is no
ingress of grout or other extraneous material into the joint annulus after the joint has been
made.
2. Where pipes with flexible joints are required to be laid to curves, the deflection at any joint as
laid shall not exceed three quarters of the maximum deflection recommended by the
manufacturer.
5.8 WELDED JOINTS IN PLASTIC PIPES
1. Fusion welded joints in high density and medium density polyethylene pipes shall be made
only between pipes having the same physical characteristics. Joints between pipes from
different manufacturers shall only be made with the specific approval of MWC.
2. When solvent welded u-PVC pipes are jointed outside the trench, they shall not be lowered
into place until the period recommended by the manufacturer for complete setting of the joints
has elapsed.
3. A pipe section containing a completed weld shall achieve the same strength characteristics
as the parent pipe.
4. Butt fusion and electrofusion joints in polyethylene pipes shall be carried out entirely in
accordance with manufacturer’s instructions.
5.9 BUTT FUSION JOINTING IN POLYETHYLENE PIPELINES
1. In the following specification and procedure terms used are defined as:
a) Drag Pressure (Pd) – The ram pressure necessary to just overcome the frictional
drag and cause the pipe to move continuously.
b) Fusion Pressure – The ram pressure required to generate 0.15 Mpa interface stress.


c) Heat Soak – The period in seconds during which the pipe ends are left to “soak”
against heater plate, with the ram pressure between 0 and Pd.
d) Welding Pressure – The sum of Drag Pressure and Fusion Pressure.
2. Two district butt fusion welding techniques shall be employed:
a) Single Pressure procedure for MDPE pipes < 315mm diameter and HPPE pipes,
250, 280 and 315 diameter of SDR = 11.
b) Dual pressure procedure for MDPE pipes > 315 and HPPE pipes of 250, 280 and
315mm diameter with SDR = 11.
3. The welding machine shall have a frame containing clamps, which are sufficiently robust to
reround the pipe to be joined; the clamps shall be accurately aligned.
4. Generally, pipes shall be put in the machine with the manufacturer’s markings aligned.
5. The machine shall have a minimum of two rams mounted on the pipe centerline axis. The
interface stress generated by the rams will be a maximum of 0.15 N/mm2.
6. Using the procedure outlined, the Contractor must calculate the machine cylinder pressures
to achieve the interface stress specified (after allowance for ‘drag’). The calculated pressures
for each pipe size must be clearly indicated in a table either held by the welder or attached to
the machine. An example of such a table is shown as Table 3.
7. The rams shall move freely under a constant pressure and control the movement of any
sliding clamps. All slides must be free from rust and kept well maintained and lightly
lubricated.
8. The machine must incorporate a mechanism for alignment and automatic releasing of the
heater plate from the heated weld surfaces.
9. Adequate power shall be supplied to the planning tool such that continuous swarf of uniform
thickness is removed during planning. The trimming blades of the planer shall be sharp and
have defect-free cutting edges. They shall be kept clean at all times.
10. When in use, the planer shall be mounted securely within the frame of the welding machine
such that there is no tendency for the tool to twist during machining.
11. The heater plate shall be made from aluminum or alloy and be uniformly coated `with PTFE
having adequate release properties. Release agents will not be allowed.
12. The PTFE coating shall be colored to show any contaminants. The plate shall be electrically
heated and be provided with a calibrated thermostatic controller.
13. The heater plate must be aligned square to the pipe ends, such that there are no gaps
greater than 0.5mm when the pipe is pushed against the plate under drag pressure.
14. The heater plate generator shall have adequate power supply at 110 v to deliver sufficient
heat to maintain the plate surface temperature at between 2250C and 2400C when cold pipe
is in contact with the plate.
15. The plate surface temperature shall be measured at several points at the section to be in
contact with the pipe.


16. A protective holder that shields the plate against draught and dust contamination shall be
provided for the plate when not in use. It must be used at all times to store the plate. The
holder shall not contain any loose or fibrous material that could contaminate the plate. It
must be kept clean at all times.
17. Only approved debeading tools will be permitted. Any such tool shall be demonstrated to
debead without notching the pipe and shall remove the bead in a continuous strip. Welds
may only be debeaded when they have cooled to ambient temperature.
18. Ram pressures must be monitored on a calibrated gauge of at least 50mm diameter or using
a transducer that is calibrated over a given range to 5%.
19. The range of the gauge shall be such that the combined drag and fusion pressures are not
within 20% of either gauge limit.
20. All welding shall be carried out with the equipment and operator in an approved shelter. The
shelter must provide adequate protection against rain, wind and draughts (to prevent ‘chilling’
of the plate and of pipe ends after heating).
21. The shelter shall be maintained in a neat and tidy condition and precautions taken against
accumulation of dust.
22. No welding will be permitted in the open air without cover.
23. Prior to inserting the heater plate, the far ends of the pipes shall be covered to prevent any
cooling of the plate by internal draughts.
24. For in trench welding all surface water shall be pumped from the trench and a shelter to
protect from rain, wind, draughts and dust shall be assembled over the working area at all
times when the welding is in progress.
25. All grease or foreign matter on the trimmer blades must be removed with isopropanol or other
approved solvent prior to trimming.
26. Prior to any welding session and after cooling to ambient temperature, the cold heater plate
must be thoroughly washed with copius quantities of clean water. Care must be taken not to
scratch the coating on the plate. Washing shall be accomplished with new paper based
tissue.
27. Grease and oil films on the heater plate surface shall be removed from the cold plate with
solvent.
28. Prior to any welding session, the Contractor shall perform a ‘dummy’ weld, using the
equipment and welder, he proposes to use for the session. MWC shall witness the dummy
weld procedure. Should the procedure and finished weld be satisfactory, MWC will permit
the session to commence. Neither the equipment nor the welder shall be changed mid
session without the approval of MWC. The dummy weld shall be handed to MWC for testing
by others.
29. Pipe cuts shall only be made using a saw having not less than 10 teeth per inch. It is
recommended that power jigsaws be used for cutting.
30. The diameter of pipes to be welded shall mate such that the maximum lip due to mismatch is
within the tolerances given in Table 1. When matching ends are outside these tolerances
then the pipe shall be re-aligned and re-machined.


31. The ends of pipes to be planed shall be cleaned with clean water on both outside and inside
surfaces to remove mud, dirt or grease. They shall then be dried using new, clean, tissues.
(Grease shall be removed with the approved solvent)
32. During planing, a continuous swarf ribbon will be obtained by the time planing ceases.
Following planing, dust and loose shavings shall be removed from the surfaces by wafting
with paper tissue. The machine surfaces shall not be touched by hand or clothing.
33. When the machined surfaces are matched together under fusion pressure (Pf) there should
be no gap greater than 0.25mm.
Single Pressure Welding Procedure:
34. For each weld to be undertaken the Drag Pressure (Pd) shall be measured three times, the
average calculated and this shall be recorded as the Drag Pressure.
35. Heating. The pipe shall be pressed against the heater plate to form the initial bead using a
total pressure equal to the fusion pressure (Pf) to generate 0.15 Mpa interface stress plus
drag pressure (Pd).
36. The initial bead size shall be as given in Table 4 and be formed uniformly around the
circumference.
37. Heat Soak. After initial bead-up, the ram pressure shall be reduced to between 0 and drag
pressure (Pd) alone, with the pipe left to ‘soak’ against the plate for times as given in Table 4.
38. During the removal of the heater plate, no molten polymer shall stick to the heater plate. If
this occurs the weld shall be aborted, the plate cleaned and the plate surface quality
examined.
39. The maximum plate removal time, before the hot ends are brought together, shall be as given
in Table 2.
40. The hot pipe ends shall be brought together in a smooth, controlled manner within 1 to 3
secs, and the ram pressure raised to the total welding pressure (Pd+Pf).
41. The weld beads should ‘roll’ back in a uniform manner and there should be no sign of
bubbles or contamination present. The weld bead sizes shall be as given in Table 1.
42. Cooling:
a) For pipe supplied as coils on drums, the clamps may only be released and the
welded section removed after the full cooling times given in Table 4.
b) For pipes supplied as straight lengths, the clamps may be carefully released after the
cooling times given in Table 4 and the welded pipes allowed to cool further. Care
shall be taken to apply only minimal stresses before cooling is complete.
‘Dual Pressure’ Welding Procedure
43. Dual Pressure Cycle. The objective of dual pressure welding is to allow the molten polymer
(formed after heating of pipe ends) – to cool with the minimum positive pressure. Therefore,
the “conventional” fusion stress of (0.15 Mpa) is only applied for 10 secs after bringing the
pipe ends together to allow the melt on each surface to mix and a bead to form to clear any
th
contaminants from the weld interface. Thereafter the stress is reduced to 1/6 of this level.
The procedure is shown schematically in Figure 3.

44. The data outlined in Table 5 give typical machine conditions in detail:
45. For each weld to be undertaken the Drag Pressure (Pd) shall be measured three times, the
average calculated and this shall be recorded as the Drag Pressure.
46. Heating. The pipe shall be pressed against the heater plate to form the initial bead using a
pressure equal to (Pf) to generate 0.15 Mpa interface stress plus drag (Pd).
47. The initial bead size shall be as given in Table 5 and be formed uniformly around the
circumference.
48. Heat Soak. After initial bead-up, the ram pressure shall be reduced to drag pressure (Pd)
alone, with the pipe left to ‘soak’ against the plate for 10 seconds/mm wall thickness plus 1
minute. (Times given in Table 5).
49. During removal of the heater plate, no molten polymer shall stick to the heating plate. If this
occurs the weld shall be aborted, the plate cleaned and the plate surface quality examined.
50. The maximum plate removal time, before the hot ends are brought together, shall be given in
Table 2.
51. The hot pipe ends shall be brought together in a smooth, controlled manner and the ram
pressure raised to the total fusion pressure Pd+Pf.
52. The weld beads should ‘roll’ back in a uniform manner and there should be no sign of
bubbles or contamination present.
53. After 10 seconds of application of fusion pressure, the pressure shall be reduced smoothly to
the cooling pressure (Pc) = drag pressure (Pd) + 1/6 * Pf.
54. Cooling:
a) The weld shall be cooled in the machine clamps under the reduced pressure of Pc
until the maximum weld interface temperature is below 900C.
b) The clamps may be carefully released after the cooling times given in Table 5 and
the welded pipe allowed to cool further-provided that care is taken to apply only
minimal stresses before cooling is complete.
Note the following relates to both Single Pressure and Dual Pressure Procedures.
55. The external bead shall be removed from all welds using an approved de-beading tool, which
does not damage the pipe. The bead shall only be removed when cold.
56. The bead shall be uniform on both sides of the weld face and equal in size (to within  2mm).
They shall have no wrinkles or discontinuities and shall have overall dimensions as given in
Table 1.
57. On examination of the internal bead surface (and the external pipe weld surface) after de-
beading there shall be no sign of any circumferential slit detect between weld beads. It
should not be possible to separate the bead.


58. To assist in the identification of slits, the beads should be repeatedly flexed in different
locations, thus opening any slits, which may be present. If a white yielded region is visible at
the bead junction along the entire length of the bead, this is a sign of a weld with no
contamination.
59. If any defect is seen, the weld shall be rejected and cut from the pipe.
60. All further production welding shall cease until equipment has been examined and thoroughly
cleaned and further trial welds made and accepted after testing.
61. Testing of welds will be undertaken by MWC up to a maximum of 2 welds per day plus
dummy welds.
62. Records
a) The Contractor will be required to keep a daily log of welding conditions used for
each weld made.
b) Each weld must be clearly marked with the weld number at two points (approx. 1800
orientation) using a black indelible marker pen or metal stamp. (The weld numbering
format must be agreed with MWC).
c) The weld conditions outlined in Table 3 shall be noted for each weld. A copy of each
day’s records shall be given to MWC.
Table 1. Typical Welding Conditions for MDPE and HPPE
Pipe Wall Mismatch on Initial Beading Typical Final

Thickness Diameter Pressure Bead Sizes
(mm) (mm) (N/mm2) (mm)
5-12 1.0 0.15 8-12

12-18 1.0 0.15 10-15
18-25 1.5 0.15 15-20
25-35 2.0 0.15 20-30
35-45 3.0 0.15 30-40
45-60 4/4.5 0.15 30-40
0 0
*Plate Temp = 225 C to 240 C
N.B. Pipe may only be removed from clamps when the interface temperature is less than 900C.
Table 2. Plate Release Times

(assuming no air movement in proximity of welding equipment)
Ambient External Temperature Time to Remove heater Plate

0
( C) (s)
10-15 12
15+ 15


N.B. These times are maximum values
Table 3. Example of Weld Record Sheet
Contract: Contractor: ___________________
Client: Manila Water Company Welding Machine: ___________________
Welder(s): Pipe Material: ___________________
Pipe Supplier: Wall Thickness: ___________________
Pipe Dia: ___________________
Date Weld Ambient Plate Drag Fusion Soak Soak Plate Fusion Cooling
No. Temp. Temp. Pressure Pressure Pressure Time Release Time Time
0 0
C C (bar) (bar) (bar) (s) Time (s) (mins)
(8)


Single Pressure Butt Fusion Welding Conditions for MDPE & HPPE: 90mm to 315mm
Machine: Fusion Eqpt. BF4 (Mk2) Effective Cylinder Area (cm)2: 17.1
Heater Plate Surface Temperature: 2250C to 2400C
Table 4
Cooling Times (minutes)

Bead Up Pressure (bar)
Cooling Time (minutes)

Cooling Pressure (bar)
Fusion Pressure (bar0
Initial Bead Size (approx) (mm)
Out of Clamps
Outside Diameter (mm)
After 10 sec.
Wall Thickness (mm)
Soak Time (records)
Soak Pressure (bar)
in Clamps
SDR
comple
cooling
cooling
clamp
clamp
Coils,
Coils,
Drag
Drag
Drag
until
until
Add
Add
Add
ted
90 26 3.5 0.8 2 95 Drag 0.8 0.8 10.0 5.0
90 17.6 5.1 1.2 2 110 Drag 1.2 1.2 10.0 5.0
90 11 8.2 1.8 2 140 Drag 1.8 1.8 10.0 5.0
110 26 4.2 1.2 2 100 Drag 1.2 1.2 10.0 5.0

110 17.6 6.3 1.8 2 125 Drag 1.8 1.8 10.0 5.0
110 11 10.0 2.8 3 160 Drag 2.8 2.8 10.0 5.0
125 26 4.8 1.6 2 110 Drag 1.6 1.6 10.0 5.0

125 17.6 7.1 2.3 2 130 Drag 2.3 2.3 10.0 5.0
125 11 11.4 3.6 3 175 Drag 3.6 3.6 10.0 5.0
160 26 6.2 2.6 2 120 Drag 2.6 2.6 10.0 5.0

160 17.6 9.1 3.8 2 150 Drag 3.8 3.8 10.0 5.0
160 11 14.5 5.8 3 205 Drag 5.8 5.8 10.0 5.0
180 26 6.9 3.3 2 130 Drag 3.3 3.3 10.0 5.0

180 17.6 10.2 4.8 3 160 Drag 4.8 4.8 10.0 5.0
180 11 16.4 7.4 3 225 Drag 7.4 7.4 10.0 5.0
225 26 8.7 5.2 3 145 Drag 5.2 5.2 10.0 5.0

225 17.6 12.8 7.5 3 190 Drag 7.5 7.5 10.0 5.0
225 11 20.5 11.5 3 265 Drag 11.5 11.5 10.0 5.0
250 26 9.6 6.4 3 155 Drag 6.4 6.4 10.0 5.0

250 17.6 14.2 9.2 3 200 Drag 9.2 9.2 10.0 5.0
250 11 22.7 14.2 3 288 Drag 14.2 2.4 15.0 7.5
280 26 10.8 8.0 3 170 Drag 8.0 8.0 10.0 5.0

280 17.6 15.9 11.6 3 220 Drag 11.6 11.6 10.0 5.0
280 11 25.5 17.9 3 315 Drag 17.9 3.0 15.0 7.5
315 26 12.1 10.1 3 180 Drag 10.1 10.1 10.0 5.0


315 17.6 17.9 14.7 3 140 Drag 14.7 14.7 10.0 5.0
315 11 28.6 22.6 3 345 Drag 22.6 3.8 15.0 7.5
Dual Pressure Conditions Needed for Pipes Shown as Shaded

Dual Pressure Butt Fusion Welding Conditions for MDPE & HPPE: 355mm to 1000mm
Machine: Fusion Eqpt. BF6 Effective Cylinder Area (cm)2: 27.86

Heater Plate Surface Temperature: 2250C to 2400C
Table 5
Bead Up Pressure (bar)
Cooling Pressure (bar)

Fusion Pressure (bar)
Cooling Time (minutes) in Clamps
Cooling Times (minutes) Out of

Initial Bead Size (approx) (mm)
After 10 sec.
Outside Diameter (mm)
Wall Thickness (mm)
Soak Time (records)
Soak Pressure (bar)

Add Drag
Add Drag
Add Drag
Clamps
SDR
355 26 13.7 7.9 3 195 Drag 7.9 1.3 10.0 5.0

355 17.6 20.2 11.4 3 260 Drag 11.4 1.9 15.0 7.5
355 11 32.3 17.6 3 385 Drag 17.6 2.9 15.0 7.5
400 26 15.4 10.0 3 215 Drag 10.0 1.7 10.0 5.0

400 17.6 22.7 14.5 3 285 Drag 14.5 2.4 15.0 7.5
400 11 36.4 22.4 3 425 Drag 22.4 3.7 20.0 10.0
450 26 17.3 12.7 3 235 Drag 12.7 2.1 10.0 5.0

450 17.6 25.6 18.4 3 315 Drag 18.4 3.1 15.0 7.5
450 11 40.9 28.3 3 470 Drag 28.3 4.7 20.0 10.0
500 26 19.2 15.6 3 250 Drag 15.6 2.6 10.0 5.0

500 17.6 28.4 22.7 3 345 Drag 22.7 3.8 15.0 7.5
500 11 45.5 35.0 3 515 Drag 35.0 5.8 20.0 10.0
560 26 21.5 19.6 3 275 Drag 19.6 3.3 10.0 7.5

560 17.6 31.8 28.4 3 380 Drag 28.4 4.7 15.0 7.5
560 11 50.9 43.8 3 570 Drag 43.8 7.3 20.0 10.0
630 26 24.2 24.8 3 300 Drag 24.8 4.1 10.0 7.5

630 17.6 35.8 36.0 4 420 Drag 36.0 6.0 15.0 7.5
630 11 57.3 55.5 4 635 Drag 55.5 9.2 20.0 12.5
710 26 27.3 31.5 3 335 Drag 31.5 5.3 15.0 7.5

710 17.6 40.3 45.7 4 465 Drag 45.7 7.6 20.0 10.0

800 26 30.8 40.0 3 370 40.0 6.7 15.0 7.5
800 17.6 45.5 58.0 4 515 58.0 9.7 20.0 10.0
900 26 34.6 50.7 4 405 Drag 50.7 8.4 15.0 10.0

900 17.6 51.1 73.4 4 570 Drag 73.4 12.2 20.0 10.0
1000 26 38.5 62.6 4 445 Drag 62.6 10.4 15.0 10.0

1000 17.6 56.8 90.7 4 630 Drag 90.7 15.1 20.0 12.5
(If (ra) in (cm)2 then multiply (ra) by 100)
FIGURE 1


SINGLE PRESSURE WELDING PROCEDURE
Sing
le
Pres
sure
Wel
ding
Cycl
e for
PE
Pres
sure
Pipe
s
1. Calculate Fusion Pressure (Pf): Based on Interface Pressure=0.15Mpa, see Figure
2. Measure Drag Pressure (Pd)
3. Check Plate Surface Temperature is between 225C and 240C
4. Form Initial bead using Pressure Pf
5. Reduce Pressure to between 0 and Drag Pressure
6. Soak against Plate (for the times given in Table 5)
7. Remove Plate Swiftly
8. Build-up Pressure to Pf+Pd (in controlled manner)
9. Do not remove from Clamps until Interface is below 90C
10. Cooling Times are given in Tables 4 and 5


DUAL PRESSURE WELDING PROCEDURE
Dual Pressure Welding Cycle for PE Pressure Pipes
11. Calculate Fusion Pressure (Pf): Based on Interface Pressure=0.15Mpa, see Figure
12. Measure Drag Pressure (Pd)
13. Check Plate Surface Temperature is between 225C and 240C
14. Form Initial bead using Pressure Pf
15. Reduce Pressure to between 0 and Drag Pressure
16. Soak against Plate (for the times given in Table 5)
17. Remove Plate Swiftly
18. Build-up Pressure to Pf+Pd (in controlled manner)
19. Hold Pressure Pf for 10sec. – to allow Bead to Roll-Over
20. Decrease Pressure to (Pd+1/6*Pf) and maintain this pressure during cooling


21. Do not remove from Clamps until Interface is below 90C
22. Cooling Times are given in Tables 4 and 5
5.10 FLANGED JOINTS
1. Flanges shall be properly aligned before any bolts are tightened.
2. Jointing compounds shall not be used when making flanged joints, except that, to facilitate
the making of vertical joints, gaskets may be secured temporarily to one flange face by a
minimum quantity of clear rubber solution. Bolt threads shall be treated with graphite paste
and the nuts tightened evenly in diametrically opposite pairs.
5.11 OGEE JOINTS
1. Ogee joints shall be so made that the required jointing material fills the joint cavity. Any
surplus jointing material extruded inside the barrel shall be trimmed off and, where
practicable, pointed on completion.
5.12 WELDED JOINTS IN STEEL PIPES
1. The process of welding steel pipelines shall be in accordance with AWWA C206.
2. The ends of pipes shall be cut and prepared and free from fins, planar defects, tears and
other surface defects, prior to welding. Cleaning to base metal shall extend for at least 25mm
from the end of the pipe on both internal and external faces.
3. The alignment of abutting pipe ends shall be such as to minimize the internal offset between
surfaces.
4. The Contractor shall submit his proposed welding procedure to MWC for codifying.
5. After each welded pipe joint has been made, a coating and lining equivalent to the factory
applied coating of the adjacent pipes shall be applied across the joints.
5.13 CEMENT MORTAR JOINTS
1. In making yarn and mortar joints for pipes or fittings, the spigot shall be entered into the
socket of the last pipe laid until it bears on the back face of the socket, and it shall be
centered in the socket. Two turns of tarred yarn shall then be caulked into the back of the
socket and Type M1 cement mortar shall be pressed into the joint to fill the socket and shall
be beveled off at 450 from the outside edge of the socket.
5.14 RUN LEAD JOINTS
1. Run lead joints shall be made by forcing home strands of white sterilized jute piping yarn, to
the back of the socket cavity leaving a space of 75mm (60mm for pipes of 300mm nominal
bore and below) measured from the socket face. A suitable clip shall then encircle the socket
face or gasket and the joint cavity filled with molten lead poured in one running. After cooling,
the lead shall be set up and neatly finished with the face of the lead 2-mm back from the
socket face. In the case of pipes over 750mm diameter, the socket and spigot shall be
heated before the joint is run.
5.15 PROTECTION OF FERROUS PIPES, JOINTS AND FITTINGS


1. Ferrous pipes joints and fittings shall be cleaned and all loose rust removed before protection
is applied.
2. External protection to all ferrous pipelines in the ground shall be one of the following, as
described in the Contract. External protection to all bolted pipe joints and flange adaptors in
the ground shall be type P1.
a) P1 The application of mastic paste in sufficient quantity to cover all protruding

edges, bolt heads and sharp edges of flanges, to give a smooth external profile. The
joint or fitting shall be wrapped with two separate applications of protective tape
wound spirally with a minimum half width overlap. The taping shall extend along
150mm of the barrel of the pipe on each side of the joint or fitting.
Or
b) P2 The application of a self-adhesive rubber-based cold-applied tape wrap

combined with thick PVC backing. Where bolt heads, flanges and other projections
arise moulding putty shall be used to give a smooth external profile. The joint or
fitting shall be wrapped with two separate applications of protective tape wrap wound
spirally with minimum of half width overlap. The tape shall extend along 150mm of
the barrel of the tape on each side of joint or fitting.
Or
c) P3 The application of heat shrink sleeves. The Contractor shall ensure that any
sleeving is not torn or displaced during pipelaying and backfilling. External protection
for ductile iron pipes where specified in the Contract Specific Document shall
comprise:
d) P4 The covering of the pipes with flat polythene sheeting securely held in place with
adhesive tape at pipe joints and intermediate positions
Or
e) P5 Painting or coating the external surface as described in the Contract.
3. Completion of internal and external protection of steel shall be provided where pipes have a
bituminous, epoxy or any other type of propriety protective coating in which a gap has been
left for the joint to be made. The joint and any damage to the protective coating shall be
made good.
4. Cathodic protection of pipes, joints and fittings shall comprise either impressed current or
sacrificial anode.
5. Mild steel components and pipework and fittings exposed to air, including those manholes,
chambers and surface boxes, shall be protected externally after installation by applying two
coats of black bitumen paint to a total minimum dry film thickness of 80 m.
6. All pipework fittings which are to be within treated water compartments shall be stripped of
their external surface protection where and repainted with protective paint coats which are in
accordance with the appropriate standards.
5.16 CUTTING PIPES


1. Pipes shall be cut by a method which provides a clean square profile, without splitting or
fracturing the pipe wall, and which causes minimal damage to any protective coating. Where
necessary, the cut ends of pipes shall be formed to the tapers and chamfers suitable for the
type of joint to be used and any protective coating shall be made good, and the ends sealed.
2. Where ductile pipes are to be cut to form non-standard lengths, the Contractor shall comply
with the manufacturer’s recommendations in respect of ovality correction and tolerances to
the cut spigot end.
3. Where ductile iron pipes of 450mm and greater are specifically required to be cut for use with
fittings having fine tolerance on diameter and ovality, then only pipes purposely ordered for
cutting shall be used. These pipes are identified by the manufacturer. Cutting shall be carried
out entirely in accordance with the manufacturer’s instructions. Consequential damage to
pipe lining and coatings shall be made good, with compatible materials.
4. Where cement mortar lining has been damaged, before repairing the lining, all loosely
adhering materials shall be removed.
5. Cement mortar for repair shall be 1:2.5 cement: sand mortar.
6. The use of cut concrete or clay pipes shall be kept to a minimum.
7. The cut ends of reinforced concrete pipe shall be thoroughly cleaned and two coats of epoxy
resin coating applied to seal the end.
5.17 PRECAST CONCRETE MANHOLES
1. Precast concrete chamber and shaft sections shall be constructed with step irons, ladders or
slabs aligned correctly.
2. Joints shall be made so that the required jointing material fills the joint cavity. Any surplus
jointing material extruded inside the chamber or shaft shall be trimmed off and joints shall be
pointed on completion. The jointing material shall be Class M1 mortar.
3. Where manholes are to have surround, the concrete shall be Class A and the height of each
concrete pour shall not exceed 2 m. Each construction joint shall break joint with that of the
chamber or shaft sections by at least 150mm.
5.18 PRECAST CONCRETE SEGMENTAL MANHOLES
1. Precast concrete segmental manholes shall be constructed in accordance with the relevant
provisions of ASTM-C76.
5.19 BRICK AND IN-SITU CONCRETE MANHOLES AND CHAMBERS
1. Manholes and chambers in brickwork or in-situ concrete shall comply at least with the
relevant provisions of this SES.
2. Brick chambers are to be constructed using the bond indicated on the drawings. A relieving
arch shall be provided over pipes exceeding 300mm diameter.
5.20 INVERTS AND BENCHING
1. Manhole inverts and benching shall be formed of the materials described in the Contract and
where there is no change of diameter, the invert shall follow the same gradient as the
outgoing sewer.

2. Where inverts and benching are to be formed of in-situ concrete or high strength concrete
topping, the relevant sections shall apply.
3. Where a high strength concrete topping is required, the invert and benching shall be formed
in Class A (24 MPa) concrete with a Screeded Finish or Rough Finish as required, and the
concrete topping shall be applied as soon as practicable thereafter.
4. Where the finished surface is to be in-situ concrete, the concrete shall be Class A with a
Steel trowel or Fair Worked Finish as required.
5. Where the inverts of both manhole and sewer are constructed of brickwork, there shall be no
break in bond between the two.
5.21 PIPES AND JOINTS ADJACENT TO STRUCTURES
1. Except where the construction is by tunneling, heading or pipe jacking, a flexible joints shall
be provided as close as is feasible to the outside face of any structure into which the pipe is
built, compatible with the satisfactory completion and subsequent movement of the joint.
2. The length of the next pipe (rocker pipe) away from the structure shall be in the range 0.5
meter to 0.75 meter for pipes up to 450mm nominal bore and shall not exceed 1 meter for
pipes up to 750mm nominal bore.
3. A pipeline may, where practicable, be laid through a manhole and the crown cut out to the
half diameter, provided flexible joints are situated on each side no farther than 600 mm from
the inner face of the manhole wall, and that adjacent pipes comply with Sub-clause 2 of this
clause.
5.22 WATERTIGHTNESS OF MANHOLES AND CHAMBERS
1. Manholes and chambers shall be substantially watertight, with no identifiable flow of water
penetrating the permanent Work.
5.23 SETTING MANHOLE COVERS AND FRAMES
1. Manhole frames shall be set to the required level on brickwork, or on precast concrete cover
frame seating rings, as described in the Contract. The frames shall be set to level, bedded
and haunched over the base and sides of the frame in Class A concrete.
5.24 CONNECTIONS TO EXISTING SEWERS
1. Pipe saddles for concrete or clay sewers shall be bedded in Class M1 mortar and a mortar
fillet formed to give a cover of at least 50mm to the base of the saddle. Pipe saddles for
asbestos-cement sewer pipes shall be formed from asbestos-cement and fixed with an epoxy
resin adhesive.
2. Pipe saddles for uPVC pipes shall be purpose made from uPVC and shall either be of a
mechanical clip-on type or shall be fixed with appropriate solvent cement.


3. Where an appropriate saddle or junction unit is unobtainable a connection to an existing
sewer may be made with a pipe cut to give an oblique junction, so that the discharge is in the
direction of flow in the main sewer. The connecting pipes shall be of such a length that the
socket of the cut pipe rests on the outside barrel of the sewer with no projection inside the
main sewer. The pipe joint shall then be pointed in Class B mortar externally and internally
where practicable. Alternatively, purpose made junctions may be used by cutting out
sections of pipe, fitting a junction and securing with repair coupling.
4. The ends of connections and pipes not required for immediate use shall be closed with
purpose made stoppers, discs or joinders. The position of all junctions shall be recorded by
the Contractor by measurement from the manhole immediately downstream and notified to
MWC before backfilling is commenced.
5. Pipe connections within the Work shall be formed using standard preformed junctions where
possible. Saddle connections to existing sewers shall only be allowed when the internal
diameter of the major pipe is at least 150mm greater than the branch pipe internal diameter.
If the major and branch pipe sizes are such that the difference in pipe size is less than
150mm, a standard preformed junction shall be fitted into the major pipe run.
6. Saddle connections shall generally be fitted at 450 to both the horizontal and longitudinal axes
of the main pipe and the hole made in concrete and clayware pipes with a diamond hole
cutter of the appropriate size and angle. All connection shall be surrounded with 150mm of
Class B concrete.
5.25 SEWERS AND MANHOLES TO BE ABANDONED
1. Grout for filling abandoned sewers shall be Class G4 with the addition of a fast setting agent.
Grouting operations shall proceed such that no length of sewer shall be filled until all
upstream communicating lengths have been completed.
2. The seals at the lower end of each run of sewer shall be fitted with a flexible breather pipe,
fixed at the soffit of the sewer and turned vertically upwards to a height of 600mm above the
soffit level of the higher end of the relevant sewer length.
3. The head of existing sewer lengths “cut-off” and exposed during excavations for new work
shall be suitably sealed and a 150mm flexible injection pipe, constructed through the seal at
the soffit of the sewer, shall be turned vertically and extend upwards for at least 1 m.
4. On completion of grouting operations the injection pipe shall be sealed with a plug of
concrete at least 150mm deep having 150mm bearing outside the injection pipe.
5. The shafts of manholes on abandoned sewers shall be broken down to a level of 1 m (1.5
meters in highways) below finished ground level and the remaining void filled with lean
concrete, deposited in layers not exceeding 225mm unconsolidated thickness, fully
compacted and brought up to level (in roads the underside of the sub-base).
5.26 PIPE JACKING
1. Excavation for pipe jacking shall be undertaken from within a shield equipped with steering
jacks for adjusting the alignment. Face boards shall be available for boarding up the exposed
excavation.
2. The Contractor shall provide such continuous superintendence as is necessary to maintain

the line and level during jacking of the pipe.


3. The Contractor shall limit the jacking load applied to the pipeline such that damage to the
pipes is avoided and in this connection he shall be responsible for deciding whether an
intermediate jacking station is needed.
4. The jacking load shall be transferred to the pipes through a thrust ring, which shall be
sufficiently rigid to ensure even distribution of the load.
5. The pipe manufacturer’s described permitted draw or angular deflection in relation to the
product standards and shall not be exceeded at any individual joint.
6. The Contractor shall monitor graphically the relationship between the jacking force and
distance moved. From this information the Contractor shall anticipate measures necessary to
avoid exceeding the maximum permitted jacking forces. The Contractor shall provide MWC
with daily records of the jacking force required to advance each pipe length. The jacking
force instrumentation shall be calibrated on site and the Contractor shall provide MWC with
the calibration certificate.
7. All lifting holes and grouting holes shall be sealed with Class M1 mortar.
8. Unless otherwise required by the Contract that joint packing designed to distribute the jacking
load evenly shall be inserted at and between the pipe ends and at any intermediate jacking
stations.
9. Where grouting is required this shall be carried out in accordance with Clause 5.33 after the
pipes have been jacked into their final position.
10. The Contractor shall provide MWC with all calculations and design details for each jacking
station. Before work may start on any thrust pit the Contractor shall demonstrate to MWC
that the design will withstand the maximum jacking forces of which the jacks are capable.
11. Before a particular pipe jack may commence evidence that the pipes necessary for the
completion of the jack are either on site or in storage elsewhere must be available for
inspection by MWC. The envisaged number of intermediate jacking stations must be agreed
in advance for commencement. At least one intermediate jacking station assembly shall be
available at the start of the pipe jack unless otherwise agreed by MWC.
12. On making a joint the pipe to be jacked shall be rotated to minimize the effects of pipe end
squareness.
13. Pipes, including lead pipes, which have been jacked through a pipe jack, may not be used
elsewhere on the Work. Cut pipes may not be jacked.
14. The jacking load applied shall not exceed the design strength of any pipe being jacked.
15. Intermediate jacking stations shall be inserted when the main thrust pit jacking force reaches
75% of the pipe design load unless MWC has authorized, in writing, that such an interjack
station is not required.
16. To safeguard against the opening of installed joints the Contractor shall ensure the pipeline
does not move in any direction when the jacking loads are removed. This requirement
should be borne in mind on drives where it is necessary to maintain a face pressure.


17. On completion of the drive intermediate-jacking stations must be left fully closed. All jacks,
props, thrust rings and packing must be removed, the ends of the pipes cleaned, a new
packing ring glued to the receiving face and the joint jacked partly closed. An “O” ring seal
shall then be inserted into the sliding joint and the joint jacked fully closed. The order of
closing stations shall be from the tunneling shield working back.
18. The annular space between the sides of the excavated tunnel and the jacking pipes shall be
constantly filled with bentonite grout at a pressure, which will support the adjacent
excavation. The Contractor shall provide MWC with daily records of the quantity of bentonite
used for each length of pipe thrust and the point at which the bentonite was injected. The
bentonite shall be thoroughly mixed and given sufficient time to fully absorb water and to
swell prior to pumping or placing.
19. On completion of the pipejack the annulus shall be filled by the displacement of the bentonite
with grout.
5.27 SHAFTS
1. The Contractor shall provide temporary ladders to all shafts, with landings at intervals not
exceeding 6 m. Protection shall be so provided that neither the ladders, landings, supporting
structures nor persons using them are subject to the risk of damage or injury by the passage
of skips and/or materials in the shaft.
2. Segments used in shafts shall so erected as to break vertical joint except in any rings
required to be broken out.
3. Where shafts are constructed by underpinning and lined with segments, they shall be grouted
up at least once per shift.
4. After any primary lining is complete and before any openings are made at or near the foot,
the excavation for the base of the shaft shall be taken out and the base concrete.
5.28 OPENINGS IN SHAFTS AND TUNNELS
1. The Contractor shall supply to MWC drawings showing his proposals for forming opening in
shafts and tunnels. These drawings shall include details of temporary supports to the lining
and to the ground.
2. Openings in shafts and tunnels shall only be made after the segments have been grouted.
5.29 SEGMENTAL SHAFT AND TUNNEL LININGS
1. Before each ring of any segmental lining is erected, any loose material or other obstruction
shall be removed from any exposed Final Surface.
2. Segments shall be erected and assembled in-situ ring by ring and joint faces shall clean on
erection. The lining shall be built as soon as possible after the ground has been cut.
5.30 UNBOLTED CONCRETE TUNNEL SEGMENTS
1. The shape of unbolted concrete tunnels shall be maintained within tolerance after erection,
until the segments have been established by grout or other means.


2. Where a circumferential pre-stress is applied, the force shall be such that the whole of the
concrete lining is expanded tight against the surrounding ground. An approved graphite
compound shall be applied to the wedge faces of segments immediately prior to expanding
the ring.
3. Where wedge block segments are specified, the excavated tunnel periphery shall be
lubricated to reduce skin friction.
4. Where key segments are shorter than other segments comprising the ring, the pockets
formed shall be filled with Class B (17 MPa) concrete.
5.31 BOLTED CONCRETE SEGMENTAL LININGS
1. Segmental joints to bolted concrete tunnel and shaft linings shall be true and longitudinal
joints bolts tightened before the final tightening of the circumferential joint bolts connecting
the ring to the adjacent ring.
2. Bituminous jointing strip shall be provided to longitudinal joints.
3. Packing shall be inserted in the joints of the lining at the time of erection, as required, to
maintain correct shape, line and level.
4. Two grummets shall be threaded on each bolt to be grummetted, at the time any bolted
segment is erected. One grummet shall be placed under the washer at the head of the bolt
and the other under the washer at the nut.
5. Connectors between segments shall be designed and installed such that if they corrode they
will not cause spalling of the segments.
5.32 GROUTING OF SEGMENTS
1. Segmental shaft and tunnel linings shall be grouted by forcing the required grout through the
grouting holes in the segments, so that all interstices around the outside of the segments are
filled. Adequate venting shall be provided to ensure that air is not trapped. Grouting shall
closely follow the erection of rings and shall be undertaken at least once per shift.
2. Temporary hardwood plugs shall be inserted into grout holes after grouting; these shall be
replaced by permanent plugs of material similar to that of the segments being grouted when it
is evident to MWC that grouting has been effective.
3. Grout pipes shall be provided in head walls or ring walls and any void remaining after
concreting shall be filled with the required grout.
5.33 CAULKING
1. Caulking of segment joints in tunnels and shafts shall be carried out as late as practicable
within the construction program; the grooves shall be raked out and cleaned immediately
before caulking.
2. Caulking of circumferential and longitudinal joints shall be bonded to form a homogenous and
continuous mass consolidated to fill the recess up to the inner surface of the segment or to
the depths described in the Contract.
5.34 POINTING OF JOINTS


1. Where joints between segments are required to be pointed, they shall be raked out, cleaned,
filled with a proprietary non-shrink cement mortar and pointed flush.
5.35 SHAFTS AND TUNNEL TO BE WATERTIGHT
1. Shafts and tunnels shall be substantially watertight, with no identifiable flow of water
penetrating either the primary or secondary lining.
5.36 RECORDING INFORMATION
1. The Contractor shall keep records of the line; level and the diameter measured horizontally
and vertically of any tunnel lining and shall give copies of these records daily to MWC.
Similar records shall be kept and supplied for shafts and for pipe jacking.
5.37 JUNCTIONS AND LATERALS ON SEWERS
1. Laterals shall be laid from the junctions to the boundary of the properties.
2. Junctions and laterals shall be effectively sealed with an end cap, the location of which shall
be positively indicated.
5.38 MARKER AND INDICATOR POSTS
1. Marker posts shall be erected on the route of the pipeline and indicator posts at the location
of valves and other fittings, where shown.
2. Permanent ground markers shall be constructed at locations shown. A schedule of co-

ordinates of the ground markers shall be supplied to MWC on completion of the Contract.
5.39 TOLERANCES FOR PIPELINES, SHAFTS AND TUNNELS
1. The position of the internal face of any pipeline, shaft or tunnel shall not deviate from that
described in the Contract by more than the following permissible deviations:
Work category Dimensions or Alignment Possible Deviation
Pipeline Line and level 20 mm

Pipe jacking Line 75 mm
Level 50 mm
Shafts and chambers Vertically 1 in 300
Shafts and tunnels Finished diameter 1%
but not
exceeding
50 mm
Tunnels without
Secondary lining Line (shield drive) 75 mm
Line (hand drive) 50 mm
Level (shield drive) 50 mm
Level (hand drive) 25 mm
Tunnels with
Secondary lining Line 20 mm
Level 10 mm
Shaft, tunnel and Maximum lipping between
Sewer lining segments Edges of adjacent

Segments 5mm
5.40 SLEEVE TYPE COUPLING
1. Mating dimensions shall be suitable for the pipe to be joined and shall provide permanent
tightness and strength with flexibility. The coupling shall be complete with rubber gaskets,
nuts and bolts.
2. Installed couplings shall be coated externally with petrolatum paste wrapped with petrolatum
tapes and covered with an outer wrapping of PVC tape or roofing paper. Petrolatum tape
shall be overlapped to the recommendations of the manufacturer or a minimum of half the
width of the tape and extended to 300mm beyond its side of the coupling.
3. The Contractor shall submit samples of petrolatum paste and petrolatum tape proposed
along with the manufacturer’s brochures giving engineering data, application
recommendations, and other instructions necessary for a satisfactory application. Protection
proposed shall have been in use for at least 5 years.
5.41 JOINTING FOR BELL AND SPIGOT RUBBER RING
1. Bell and spigot shall be cleaned and carefully examined.
2. Lubricate the rubber ring gasket thoroughly with a vegetable compound soap before placing
into position and at the same time lubricate the inside face of the bell or the spigot end.
3. Ensure that the rubber ring gasket is properly seated in the spigot groove with a uniform
tension is maintained around its entire circumference, or in the bell end as applicable.
4. Ensure that the spigot enters the bell in correct straight alignment, and not at an angle. After
engagement, the joint may be deflected in accordance with manufacturer’s
recommendations.
5. Pipe of sufficient size to admit a man shall have a gasket checked for correct position with a
feeler gauge from the inside of the pipe, particular attention being given to the bottom half of
the pipe. Temporary steel or wood inserts shall be placed between the tip of the spigot and
seat of the bell to provide a space for use of the feeler gauge around the entire circumference
of the joint. Upon determination that the gaskets in its proper position, all joint spacers shall
be removed and the spigot pushed into the bell to its fullest extent as recommended by
manufacturer. The gasket position for pipe of smaller size shall be examined around the
entire circumference from the outside.
6. Joints of pipe 600mm diameter and larger shall be pointed on the inside with (one (1) part
cement to three (3) parts sand) cement mortar after the backfill has been placed.

5.42 INTERCONNECTION BETWEEN PIPES
1. At points of connection to existing mains, the Contractor shall excavate and inspect the pipe
or valves to determine the material type and make measurements. Following measurements,
the hole shall be backfilled and the surface temporarily restored with asphalt pavement.
2. Based on the field data, the Contractor shall prepare and submit sketch for MWC’s approval.
3. Where called for on the Drawings, the Contractor shall supply and install specific fittings as
well as any other fittings required for interconnections. Where specific fittings are not called
for, connection can be made by use of a tee, saddle tap, direct tap, direct welding or other
means appropriate to the type of pipe being used.
4. Generally, the connections will be made with the pressure at the existing mains reduced to
zero unless it would not be possible to do so. The Contractor shall coordinate with
concerned MWC units regarding the locations of all valves required to shut down and provide
the means for checking the valves to be sure that they are operable. MWC will provide
assistance in developing this plan.
5. Prior to any connection work, the Contractor shall notify MWC of his intention to commence
the particular work. No interconnection work shall be commenced unless an approval by
MWC has been given in writing.
6. The Contractor shall inform MWC regarding the expected duration of any water service
shutdown due to his interconnection work. However, shutdown of any watermain for a period
exceeding twenty four (24) hours will not be permitted. For its part, MWC shall notify all
consumers in the area who will be affected by any water interruption.
7. Before starting the work that may interfere with the existing water service distribution, the
Contractor shall do all possible preparatory work, including the availability of tools, materials,
labor and equipment that will be required to complete the work.
8. Maximum sanitary precautions shall be exercised by the Contractor during interconnection

work in order to guard against any health hazard that could precipitate if without due care and
precautions being undertaken.
5.43 PIPE SUPPORTS
1. The Contractor shall submit to MWC, shop drawing of pipe support he intends to adopt for
construction purposes.
5.44 SERVICE CONNECTIONS
1. Service connections shall be with corporation stop or ferrule.
2. Corporation stop shall be tapped at a 45 degree angle pointing upward. Ferrules shall be
tapped at the top of the watermains.
3. Service connection tubing may be installed under concrete pavement by boring horizontally
beneath the paved surface at the Contractor’s option. The Contractor shall prove and
demonstrate that his method will not disturb the existing pavement and base course nor
cause settlement that will damage the road surfaces and shall be to MWC’s approval. If
method involves jacking a temporary casing, the casing may not be withdrawn if such

operation shows any danger of damage to the pavement or service connection. Boring by
water jetting is not permitted.


Construction of Pipelines, Tunnels and Ancillary Work

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SECTION 5

CONSTRUCTION OF PIPELINES, TUNNELS AND ANCILLARY WORK

a) Cast Iron and Ductile Iron Pipe - Standard C600

MWC Standard Engineering Section 05 Construction of pipelines, Version 01

Waste Water Page 1 of 26 Date: October 2009

5.3 CONCRETE PROTECTION TO PIPES

1. Pipes to be bedded on or cradled with concrete shall be supported on pre-cast concrete

5.4 COMPLETION OF PIPE SURROUND

5.5 PIPELAYING IN HEADINGS

MWC Standard Engineering Section 05 Construction of pipelines, Version 01

Waste Water Page 2 of 26 Date: October 2009

5.7 PIPE JOINTING GENERALLY

5.8 WELDED JOINTS IN PLASTIC PIPES

5.9 BUTT FUSION JOINTING IN POLYETHYLENE PIPELINES

MWC Standard Engineering Section 05 Construction of pipelines, Version 01

Waste Water Page 3 of 26 Date: October 2009

d) Welding Pressure – The sum of Drag Pressure and Fusion Pressure.

2. Two district butt fusion welding techniques shall be employed:

MWC Standard Engineering Section 05 Construction of pipelines, Version 01

Waste Water Page 4 of 26 Date: October 2009

22. No welding will be permitted in the open air without cover.

MWC Standard Engineering Section 05 Construction of pipelines, Version 01

Waste Water Page 5 of 26 Date: October 2009

Single Pressure Welding Procedure:

‘Dual Pressure’ Welding Procedure

Waste Water Page 6 of 26 Date: October 2009

MWC Standard Engineering Section 05 Construction of pipelines, Version 01

Waste Water Page 7 of 26 Date: October 2009

Table 1. Typical Welding Conditions for MDPE and HPPE

Pipe Wall Mismatch on Initial Beading Typical Final

5-12 1.0 0.15 8-12

Table 2. Plate Release Times

Ambient External Temperature Time to Remove heater Plate

MWC Standard Engineering Section 05 Construction of pipelines, Version 01

Waste Water Page 8 of 26 Date: October 2009

Table 3. Example of Weld Record Sheet

Contract: Contractor: ___________________

Client: Manila Water Company Welding Machine: ___________________

Welder(s): Pipe Material: ___________________

Pipe Supplier: Wall Thickness: ___________________

Pipe Dia: ___________________

MWC Standard Engineering Section 05 Construction of pipelines, Version 01

Waste Water Page 9 of 26 Date: October 2009

Cooling Times (minutes)

Cooling Time (minutes)

Soak Time (records)

Soak Pressure (bar)

110 26 4.2 1.2 2 100 Drag 1.2 1.2 10.0 5.0

125 26 4.8 1.6 2 110 Drag 1.6 1.6 10.0 5.0

160 26 6.2 2.6 2 120 Drag 2.6 2.6 10.0 5.0

180 26 6.9 3.3 2 130 Drag 3.3 3.3 10.0 5.0

225 26 8.7 5.2 3 145 Drag 5.2 5.2 10.0 5.0

250 26 9.6 6.4 3 155 Drag 6.4 6.4 10.0 5.0

280 26 10.8 8.0 3 170 Drag 8.0 8.0 10.0 5.0

315 26 12.1 10.1 3 180 Drag 10.1 10.1 10.0 5.0

Waste Water Page 10 of 26 Date: October 2009

Dual Pressure Conditions Needed for Pipes Shown as Shaded

Machine: Fusion Eqpt. BF6 Effective Cylinder Area (cm)2: 27.86

Bead Up Pressure (bar)

Cooling Pressure (bar)

Cooling Time (minutes) in Clamps

Cooling Times (minutes) Out of

Wall Thickness (mm)