ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)

FOR DUCTILE IRON FITTINGS

 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
FITTINGS - DUCTILE IRON document: W-P-QCP-011
(FOR POTABLE WATER PIPELINE WORKS) Page 1/16 Date
Document References : Sep-15
ISO 9001 : 2000 - Quality management systems - Requirements
EN 545 : 2006/ 2010 - Ductile iron pipes, fittings, accessories and their joints for water pipelines - Requirements and tests methods
ISO 2531 : 1998/ 2009 - Ductile iron pipes, fittings and accessories and their joints for water or gas applications
ISO 2859 : Part 1 : 1999 - Sampling procedures for inspection by attributes.
ISO 4179 : 2005 - Ductile iron pipes & fittings for pressure and non pressure pipelines – centrifugal cement mortar lining.
ISO 4633 : 2002 - Rubber seals – Joint rings for water supply, drainage and sewerage pipelines – Specification for materials
ISO 6506 : Part1 : 2005 - Method for the Brinell hardness test for metallic materials
ISO 7005 : Part 2 : 1988 - Metallic flanges - Cast iron flanges
ISO 8179 : Part 1 : 2004 - Ductile iron pipes- external zinc-based coating : Metallic Zinc with finishing layer (Also applicable to fittings)
ISO 8179 : Part 2 : 1995 - Ductile iron pipes- external zinc coating : Zinc Rich Paint with finishing layer (Also applicable to fittings)
ISO 8501 : Part 1 : 1988 - Preparation of steel substrates before application of paints and related products
EN 1092 : Part 2 : 1997 - Flanges and their joints : Cast iron flanges
EN 10204 : 2004 - Metallic products – Types of inspection documents
EN 15189 : 2007 - Ductile iron pipes, fittings and accessories, External polyurethane coating for pipes

ADWEA Standard Specification for Water Works

This document addresses the minimum Quality Assurance and Quality Control requirement during the manufacturing of fittings in the manufacturer’s plants for the Contract.

The contents of the Contract Documents including Technical Data Sheet (TDS) shall be read in conjuction with this SQCP.
Abbreviations:
R = 100 % Review of documents, T = Test (Controls including Visual, Dimensional, Destructive or Non Destructive Test), W = Witness point, H = Hold point
Man = Fitting Manufacturer and/or Supplier, TPIA = Third Party Inspection Agency, ADWEA = Abu Dhabi Water & Electricity Authority / Affiliated Company, ADWEA/Consultant = Consultant
Company delegated by ADWEA for the specific project, Client/Owner: ADWEA, Cont.: Contractor.
Manufacturer inspection frequency : The actual inspection frequency shall be as stated in this document, but in any case not less than what is specified in the contract documents.
Witnessing/reviewing by TPIA : All quantified measurement checks/tests carried out shall be recorded on the applicable Manufacturer’s Quality control sheets for witnessing/reviewing
by the TPIA in line with this SQCP requirements.

IMPORTANT
NO CHANGES, WAIVER OR CONCESSIONS SHALL BE MADE IN THIS SQCP AND ITS REQUIREMENTS
BY ANY INDIVIDUAL OR PARTY UNLESS EXPLICIT PERMISSION IS GIVEN IN WRITING BY ADWEA.
Prepared by Reviewed by Approved by

SKN ADWEA Review team AMD

 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
NOTES:
a) ADWEA may modify this SQCP document should non-compliance with a specific Contract be noticed at any time, or should there be a change in TPIA role.

b) Any modification for non-compliance if required, shall be as per the contract documents inclusive of the specifications, knowing that in case of conflict
between the QCP and the Contract, The Contract shall prevail.

c) SQCP activity No. 13 Factory Release Certificate ( FRC ) covers the final checking stage prior to dispatch from the manufacturing site
and is a “ Hold” point for each CONTRACTOR/TPIA and ADWEA/ TPIA.
A Common FRC shall be initiated by the Manufacturer and shall be issued for each batch of the product. The FRC shall be signed by CONTRACTOR/TPIA and ADWEA/ TPIA
Any deviation to this “Hold Point” shall render release of materials as void. The FRC shall be signed and issued only when
the items are loaded on the vehicle at the manufacturing plant ready to be transported to the exit port. At the release for shipment stage and, following the transportation
of fittings from the factory to ship / vessel loading point, Acceptance Certificate ( AC ) is required and shall be issued as per contract requirements. The activity of
loading fittings and storage within the Ship / Vessel shall form a “ Hold” point for CONTRACTOR/ TPIA and “Review” point for ADWEA/TPIA. ADWEA/TPIA may elect to
witness any or all of the activities including the transportation and handling between factory and vessel.
ADWEA / TPIA observation shall be attended to by Contractor/Supplier in line with the contract objectives and at no additional cost to ADWEA.

d) Manufacturer shall devise for approval by ADWEA, a system to trace defective Fittings with cement mortar lining cube test failure.
The quantity in question includes production from the date of sampling to the date of successive successful sample testing.

e) The processing of inspection or test by ADWEA/TPIA in accordance with this SQCP shall take place without delaying the production rate.
For this purpose, it is agreed that production of one day, offered for release shall be inspected by ADWEA/TPIA in one day. The unique serial number
of the part shall be given after acceptable coating and will be available for the TPIA on a daily basis to permit the release.

f) Prior to dispatching from manufacturing and prior to loading into the vessel CONTRACTOR/TPIA shall ensure that there are no Fittings requiring any repairs.
Repairs, if any, shall be carried out at the manufacturing site.

g) Frequency and control items of ADWEA's TPIA may be increased or decreased depending on the results obtained. These modifications are to be agreed between
ADWEA and ADWEA/TPIA prior to implementation.
h) Non toxicity certificate to be provided for all materials in contact with potable water at 60°C max. (ADWEA circular no. 5 of year 2000).

i) Inspection / Test frequency (intervention) indicated in this SQCP under Contractor/TPIA and ADWEA/TPIA columns may be invoked, waived, changed, increased or
decreased depending on ADWEA’s individual contract requirement or, when non-conformities are found or reported.

* Deployment of ADWEA's TPIA shall be at ADWEA's descretion and Deployment of Contractor's TPIA shall be as agreed / indicated in the Contract.
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 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
0 PRE-INSPECTION ADWEA / TPIA interventions,
- List and characteristics R R R See note (i) on page 2
of products of the order
- Packing and marking Acknowledgement of Order R R R * See note on page 2 of 17
instructions Review of Documents Every Order
- Applicable standards R R R

- Quality System Validity of the certificate R R R

1 Fitting System
- Fitting DN - Visual T W (100%) W (100%)
(As per Project approved TDS)

- Fitting Identification - Visual T W (100%) W (100%)

(bend taper, etc.)

- Type of joint - Visual Conformity with T W (100%) W (100%)

(As per Project approved TDS)
- Quantity
- Type test for joint leak
tightness
Each Delivery
purchase order
- Counting on Delivery T W (100%) W (100%)
- Review of Documents EN 545 T One representative type R R Type Test is a performance test
piece from each DN which is a proof that the design
Grouping as in Table test is OK. It is done only once
below. and repeated only after change of
design. Type test results to be
reviewed by the inspector.

DN grouping 40 - 250 300 - 600 700 - 1000 1100 - 2000

Preferred DN in each grouping 200 400 800 1600

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 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
2 POST CASTING ADWEA / TPIA interventions,
INSPECTION See note (i) on page 2
- External appearance Visual T
` Each Piece W (15%) W (15%)
- Internal appearance Visual EN 545 / ISO 2531 T

- Cast iron thickness Ultra-sonic gauge or other T Once per new R R

approved method according to manufacture
mould pattern and
design
any suspicious
fitting.
- Dimensions Measuring Tape T
Once per shift
and any W (15%) W (15%)
- Spigot (DE + Ovality) Gauges T suspicious fitting.

3 DUCTILE IRON TESTS

- Chemical Analysis Analysis of cast iron before
casting (ladle or channel
furnace analysis)
Production tables
T Manufacturing
Process Control
R R The chemical composition is
adjusted in order to satisfy the
material characteristics and all
requirements according to EN
545 / ISO 2531

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 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
- Tensile strength (Rm) Rp 0.2 ≥ 270 Mpa T
for (A≥12% for DN 40 - 1000) R (100%)
- Yield Strength (Rp0.2) Tensile Testing Machine and for (A≥10% for DN > 1000) T 1 per 4 Tons & R
Rp 0.2 ≥ 300 Mpa in other cases W (15%)
- Min. elongation (A%) Min Elong. A (%) T
Type of
DN 40 - DN 1100
Casting
1000 - 2600
Pipes 10 7
Fittings 5 5

- Brinell Hardness (HB) Tests in accordance with ≤ 250 HB T W (15%) R Higher HB is allowed in heat
EN ISO 6506-1 effected areas of welded
components.
4 METALLIC ZINC OR ZINC
EN 545, sec 4.5
RICH PAINT APPLICATION

- Zinc Material :
Metallic Zinc Check material type 99.99% purity for metallic zinc R Each Batch R R Metallic Zinc coating (ISO 8179-1):
Zinc Rich Paint Check Certification >85% zinc content in dry film for R Each Batch R R mean mass ≥ 200 g/m2
Check pot life & shelf life zinc rich paints local min. ≥ 180 g/m2

- Surface Cleanliness Visual T Each Fitting

Zinc Rich coating (ISO 8179 -2):
- Coating appearance Visual ISO 8179 - parts 1 & 2 T Each Fitting W (15%) W (15%) mean mass ≥ 150 g/m2
local min. ≥ 130 g/m2
- Mass (See remarks) Process control T Min. 1 / gun / shift

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No. Inspection Item
5 PRESSURE TESTING
Hydrostatic Test
(OR) Air Test
6 CEMENT MORTAR LINING
Preparation and mortar
proportions S, C, W,
additives, Weight
6.1 - Cement
- Sand (grain size
distribution)
- Sand (organic impurities
& clay bearing substances)
- Water
- S, C, W
- S/C
- W/C
ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
For Air Test :
Fittings must be properly sealed at all
ends, coated with suitable foaming
Visual according to : Fittings T Each Fitting W (15%) W (15%)
agent and internally presurised to 1
EN 545 As per ISO 2531/ EN 545 bar for 10 sec.
ISO 2531, - No leakage,
- No pressure drop OR
Fittings <DN 600 to be fully
submerged in water during test.
For flanged joint refer EN545, Sect.
5.4 for leak test Pressures.
Controls of process (weight) Production tables T Process Control W (15%) R Process to be included and
described in Material submittal
Additivies to be declered by
Manufacturer
Supplier certificate EN 197-1 or sulphat resisting T
Granulometry ISO 4179 § 3.2 & 7.2 T certificates Manufacturer shall conduct tests
from suppliers according to ISO 9001:2000
to be provided requirements
Colorimetry and ISO 4179 § 3.2 & 7.2 T
chemical tests
Potability analysis or Supplier ISO 4179 § 3.3 once every 3 months, or
T evidence that water used W (15%) R See Attachment 2
analysis
is potable water supplied
process control (weight) ISO 4179 § 3.4
by local water authority /
process control (weight) ISO 4179 § 3.4 , S/C ≤ 3.5 (by mass) utility.
process control (weight) ISO 4179 § 3.4 , W/C ≤ 0.45 (by Manufacturer to specify W/C ratio
mass) to be used.
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No. Inspection Item
6.2 Surface preparation
(Interior surface before
application of lining)
6.3 Curing
6.4 Compression strength
ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
Visual Sect. 4.1 ISO 4179 T Each Piece W (15%) W (15%)
Free from all foreign
bodies, loose scale, other
materials and any metal
projections likely to protrude
beyond 50% of the thickness of the
lining.
Visual As per curing tables T Process Control W (15%) W (15%)
(duration according to
temperature)
Test according to EN 545 ≥ 50 Mpa T 1 / month of effective W (100%) W (100%) Frequency can be increased in
A representative sample EN 545, 4.4.3.2 production, or every cases where defects are
shall be taken accordingly change in the mix detected. Refer to item d, page 2
design or the mortar of 15.
materials used.

6.5 Laitance Visual Lining free of non adhesive laitance T Each Piece W (100%) W (100%)
(NAL).

6.6 Lining Thickness According to Contract T Sampling as per W (15%) W (15%) Average is the mean of 3 or more
fabrication table readings on one piece.
depending on DN

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 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
Cont. : Lining Thickness Thickness (mm)

DN Min. at
Min.
Nominal any
average point
Dry lining method : 80 – 600 5 4.5 3.5
magnetic gauge, 200 mm 700 – 1200 6 5.5 4.5
from the end face. 1400 – 2000 9 8 7
2200 – 2600 12 10 7

ADWEA w-p-ss-001,

6.7 Mortar Lining appearance / Visual EN 545 T Each Piece W (100%) W (100%) Repair procedure to be included
adhesion / cracks inspection Cracks : and described in Material
Max. crack width Submittal
DN
(mm)
40-300 0.4 Cement mortar lining shall not
have a sealing coat
350–600 0.5
700-1200 0.6
1400-2000 0.8
- Longit. Length ≤ 100% DN.
(e.g. 1200 mm for DN 1200)

- Circumf. length ≤ 50 % of
circumference
(e.g.1885 mm for DN 1200)

6.8 Radial displacement Visual No disbondment in the factory T Each Piece W (100%) W (100%)

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 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
7 Fitting External Coating
7.1 Zinc & Finishing Layer
- Zinc : See item no. 4
- Coating Materials Check material type R Each Batch Coating Material Manufacturer’s
(Bitumen or Synthetic Resin) Check certificate recommendation shall be
As per coating included in Material submittal.
Check shelf and pot life This shall include the coating
manufacturer’s
recommendation and W (15%) W (15%) process description.
- Coating Equipment Check condition procedures T Each Equipment

- Preparation of paints Check preparation and T Each Batch

condition.

7.1.1 Fittings External ADWEA W-P-SS-001, Sect. 8.2

- Dry Film Thickness (DFT) Myler Token/Magnetic gauge Mean average DFT ≥ 120 µm (100 T 1 / spray gun / shift W (15%) W (15%) Average DFT is the mean of 10 or
(combined : Zinc + final coating) (Bituminous + Zinc coating)
µm DFT min. at any point) and 1/15 fittings for more readings on one fitting
≥ 1000
- Appearance Visual No coating defects T Each Piece W (15%) W (15%)
7.1.2 Fitting ends ( Internal Socket Same coating type as 7.1 ADWEA W-P-SS-001,
& External Spigot) above OR non-toxic solvent Mean average DFT ≥ 120 µm
free two part epoxy coating (combined DFT of Zinc + Bitumen) T 1 / 10 W (15%) Average DFT is the mean of 10 or
with thickness ≥ 300 µm (100 µm DFT min. at any point) more readings on one fitting

- Appearance Visual No coating defects T Each Piece W (15%) W (15%)

- Non Toxicity confirm that used material is Compliance with material T Each Product / Coating R
not toxic certification
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 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
7.2 Fusion Bonded Epoxy EN 14901 with the exception of : FBE coating process to be
coated fittings - Maximum water temperature shall be considered as 60 oC (ADWEA circular No. 5, year 2000) included and described in material
- The minimum thickness at any point, the minimum mean average thickness & max. thickness are as per submittal
figures below (7.2.2)
7.2.1 Performance / Type test
- Impact Resistance Drop Weight as per EN No Electrical puncture permitted T At start of production, R R
14901 Sect. 7.2.2 then upon change of
Non porosity test certificate
epoxy coat supplier or
according to EN 14901, 7.2.4 application process.
Also, applicable to
suspicious fittings.

- Indentation resistance Penetrometer as per EN Indentation depth measured after
14901 Sect. 7.2.3 48 h ≤ 30% of the initial coating
thickness Measured.
EN 14901 Sect. 6.3
T At start of production, R R
then upon change of
epoxy coat supplier or
application process.
Also, applicable to
suspicious fittings.

- Cross Linkage Methyl Iso-Butyl Ketone Limits of change as defined by T At start of production, then R R
(MIBK) test as per EN 14901 coating material manufacturer. upon change of epoxy coat
Sect. 7.1.5 supplier or application
process. Also, applicable to
suspicious fittings.

- Heat ageing Resistance Hot air ageing of bent test No electrical puncture EN 14901 T At start of production, then R R
plates EN 14901 Sect. 7.2.5.1 Sect. 6.6.1 upon change of epoxy coat
in air.
supplier or application
process. Also, applicable to
suspicious fittings.

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 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
- Heat ageing Resistance in Ageing in 70 0C hot water EN Adhesion ≥ 6MPa EN 14901 Sect. T
At start of production, then R R
6.6.2 upon change of epoxy coat
water 14901 Sect. 7.2.5.2
supplier or application
process. Also, applicable to
suspicious fittings.

7.2.2 Routine test

- Surface preparation Visual - EN 14901, 5.2 SA 2.5 as per ISO 8501-1 T Each Piece Checking of type, condition,
- Coating Appearance and Visual Uniform color, appearance, T Each Piece W (15%) W (15%) expiry, of FBE coating materials,
Continuity smoothness and free of visible equipment & preparation of
defects. EN 14901 Sect.5.3 coating shall be as in Section 7

- Adhesion test "Pull off test" according to EN Min. single value = 6 Mpa Once / Three months
ISO 4624. (EN 14901, 7.1.3) T W (15%) W (15%)
Min. Ave. value = 8 Mpa according to EN 14901,
Annex A.

- Dry Coating thickness NDT instrument using Min. at any point = 300 µm T 1 / Shift W (15%) W (15%) Average DFT is the mean of 10 or
magnetic or electro-magnetic Average DFT = 350 µm more readings on one fitting.
principle. Max. average thickness shall be
Maximum allowable DFT average = within a 40% above the min. DFT
EN 14901, 7.1.4 420 µm (EN 14901, sec 7.1.4)

The coating thickness on designated zones i.e. Bolt holes, ribs, joints, edges & markings shall be ≥ 150 µm

- Cross linking - Methyl Iso-Butyl Ketone No deviation against reference test T 1 / shift W (15%) W (15%)
As per EN 14901, 7.1.5 (MIBK) test sample

- Non Porosity (Holidays) - High voltage detector, No holidays T Each R R Except in gasket chamber
in coating
As per EN 14901, 7.2.4 2.2 kV

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No. Inspection Item
7.2.3 Non toxicity
7.3 POLYURETHANE COATING
7.3.1 Performance Type Tests :
- Chemical Resistance
- Impact Strength Test
- Indentation Resistance
- Elongation at Break
- Specific Coating Resistance,
0.1 M Na Cl solution
- Coating Resistance Ratio
ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
Review epoxy acceptance Certificate of Compliance with T Each Epoxy Product R R
certificate for contact with international regulations for
water materials in contact with water,
such as WRAS.
According to EN 15189:2006 See ADWEA w-p-ss-001 - sec.
8.4 Table 1.
De-ionised water Immersion : Less than 15% weight increase T Type Test Checking of coating materials,
Clauses 6.1 & 7.2.1.1, Table A.1 equipment & preparation of paints
shall be as in Section 7.
Diluted sulpheric acid Immersion Less than 10% weight increase T Type Test
(10% dilution) : Clauses 6.1 &
7.2.1.2, Table A.1
Dropping weight / Hight voltage 8 j/mm PU-coated pipe barrel 5 T Type Test
test Clauses 6.2 & 7.2.2, Table j/mm EP-coated spigot end (EN 14901)
A.1
R R
Indentation Test Less than 10% at 10 Mpa T Type Test
Clauses 6.3 & 7.2.3, Table A.1
Tensile Test : < 10% at 10MPa > 2.5 % T Type Test
Clauses 6.4 & 7.2.4, Table A.1
Resistivity Test : Towel method > 108 Ωm2 . Clauses 6.5 & 7.2.5, Table Type Test
or Vessel method
A.1
Res. 100 d / Res. 70 d > 0.8 Type Test
Clauses 6.5 & 7.2.5, Table A.1
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No. Inspection Item
7.3.2 Routine Tests :
- Surface Preparation
- Surface Roughness
- Appearance & Continuity
- Minimum Coating Thickness Non Destructive ; Magnetic or
- Pipe Ends Painted Parts
- Repairs
- Marking
- Non Porosity (Holidays)
- Hardness
- Adhesion
7.3.3 Fitting ends ( Internal Socket
& External Spigot )
- Non Toxicity
8 ACCESSORIES
ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
dry and clean, free of rest, loose
material, dust, oil, grease
Visual SA 2.5, EN ISO 8501-1 T 100%
According to EN ISO 8503-1 Ra > 10 µm T Min. 1 / shift
Clauses 5.1 & 7.1.1, Table A.2
Visual : 5.2.1, 7.1.2, table A.2 Uniform & smooth T 100% W (50%) W (50%)
Clauses 5.2.2 & 7.1.3, Table A.2
> 1500 µm . See Clauses 5.2.2 & T Min. 1 / shift
Electro-mag
7.1.3, Table A.2
Appropriate measures No defects. Clauses 5.3 & 7.1.4, T 10%
Table A.2
High Voltage Test Meets the non-porosity test req. T 100%
Visual Legible and durable T 10%
High Voltage detector No holiday T 1 / shift W (50%) W (50%) 10 Kv for wire mesh electrodes or
Hardness Test > 70 Shore D T Min. 1 / shift 15 Kv for conductive rubber
electrodes. For thicker coatings a
Punch separation method > 8 Mpa at 23 ºC 1 / 1000 pipes
T higher test voltage can be used.
Magnetic or Electro-Mag. Test Mean average DFT : T Each Piece W (15%) W (15%) This applies to the external spigot end
Non-toxic solvent free two part surface at a min. length of 250 mm
from face and the internal socket end
epoxy coating with DFT ≥ 300 µm
surface which may have direct contact
confirm that used material is Compliance with mat. Certification T Each Product / Coating R R with potable water.
not toxic
Conformity verification as specified in relevant documents R Each Piece W (15%) W (15%)
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 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
9 PACKAGING Marking to be cast or cold
- Appearance of pallets and Visual All according to the Manufacturer T Each Piece W (100%) W (100%) stamped on socket shall include :
boxes Technical description approved by
ADWEA 1)- Manufacturer's name
2)- Year of production
- Marking on fittings Visual For Fitting markings, whether cast T Each Piece W (100%) W (100%) 3)- DI"xx" (xx=DN in mm)
(cast-on or painted) on or painted, see the remarks 4)- PN rating of Flanges
column on the right. Markings to be Painted :
Up to 600mm : wooden boxes Visual T Each Piece W (100%) W (100%) 1)- Client name
above 600 : open crates 2)- Contract number
3)- Reference to EN 545
4)- Class of fitting
10 EPDM RUBBER GASKET
- Type Conformity to the Visual R R
order According to ISO 4633 and
- Quantity Count Technical Data Sheet. Water T R R
Each Delivery
- Packaging and Marking Visual temp. is 60 oC W (15%) W (15%)
(as required on order)
- Physical Properties Review and measure For Flanged joints, EPDM rubber T R R
gaskets shall be ≥ 3 mm and shall be
metal reinforced for pressure ratings of ≥
16 bar.

- Non toxicity Confirm the used material Compliance with material cert. T R R

11 FINAL INSPECTION by Visual According to TDS and QCP All Fittings W (100%) W (100%)
CONTRACTOR/ TPIA
Rubber Stamp of Inspector Logo All Fittings W (100%) W (100%)
(If required by ADWEA) Stamping on each controlled Fitting

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 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
12 Sampling and Measurement Each measurement is recorded Measurements to be taken by
report according to Sampling and ADWEA/ TPIA within 24 hrs as
measurement report. Measurements Tests :- a maximum.
- Dimensions
- Coating thicknesses refer to item 7 100%
- Cement thickness refer to item 6.6 100%
- Spigot diameter refer to item 2 20%
- Appearance of int. coating Visual refer to item 6.7 100%
- Appearance of ext. coating Visual refer to item 7 100%
- Result Stamping Rubber Stamp of TPIA on each 100%
controlled piece
13 FACTORY RELEASE FRC attachments :- H Every product H H This compliance certificate states
CERTIFICATE 1- Certificate of compliance delivered Release that the delivered products have
by Manufacturer (according to EN been manufactured and
- The Factory Release Cont. / TPIA verify and 10204 : inspected in conformity with
Certificate (FRC) is initiated endorse the FRC based on - Type 2.2 - For mass production Contract and QCP
and signed by the relevant inspection records Fittings
manufacturer offering the obtained throughout the - Type 3.1 or 3.2 As per ADWEA's
products for release manufacturing process in special request.
accordance with this QCP.
2- Checklist of delivery(description and Refer Page 2
- The FRC is then signed by quantity). Note c
Cont. / TPIA. 3- Certificates with material
- Once signed by Cont. / ADWEA TPIA verifies and characteristics and results of hydraulic
TPIA, the FRC along with all endorses the FRC based on tests.
supporting documentation the acceptable sampling and 4- List of the individual serial number
shall then be offered to measurements results as per of each released piece DN > 300.
ADWEA TPIA. Item 0 to 12.
5- Sampling and Measurement report
(sent by ADWEA/TPIA directly to
ADWEA).
- ADWEA/ TPIA shall implement items 0 to 13 above and
sign the FRC based on the outcome thereof and only
when the items are loaded onto the vhicle at the
manufacturing plant ready for transportation.
Doc Title Doc. No.
Date Sep-15
STANDARD QUALITY CONTRROL PLAN FOR W-P-QCP-011
DUCTILE IRON FITTINGS Rev 1
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 ADWEA STANDARD QUALITY CONTROL PLAN (SQCP)

Attachment 1 : Cement Mortar Lining

3.1 Cement
The cement used for the lining shall comply with EN 197-1 or be sulphate resisting

3.2 Sand
The sand used shall have a controlled granulometric distribution from fine to coarser elements; it shall be clean and shall be composed of inert, hard, strong and stable granular particles. The
granulometric curve for the sand shall be appropriate to the lining method, the lining thickness and the surface conditions required in Clause 6 of ISO 4179. Sampling shall be carried out in
accodance with national standards for the testing of construction materials. The cleanliness of the sand shall be evaluated in terms of organic impurities and clay-bearing substance according to the
methods described in ISO 4179. The test for organic impurities shall be carried out by a colorimetric method in accordance with the standards in force in the producing country. The sand shall not
produce any coloration darker than that of the reference solution. The determination of the content of clay-bearing substances in the sand (having dimensions less than 63 microns to 93 microns
depending on the country) shall be carried out in accordance with the standards in force in the producing country; it shall not exceed 2% by mass.

3.3 Mixing water

The water used for the preparation of the mortar shall be either potable water or water free from substances deleterious either to the mortar or to the water to be transported in the pipeline. The
presence of solid mineral particles is, however, admissibl provided that these requirements are still fulfilled. Existing national hygienic requirements have to be complied with.

3.4 Mortar
The fresh mortar of the lining shall be composed of cement, sand and water complying with 3.1, 3.2 and 3.3 respectively.
Additives may be used, provided that :-
— they do not prejudice the quality of the lining and that of the transported water.
— they comply with the hygienic requirements of the country where the fittings are to be installed.
— the lining remains in accordance with all the requirements of ISO 4179.
The mortar shall contain at least one part of cement to 3.5 parts of sand by mass (i.e. S/C ≤ 3.5 by mass in the mortar). The respective proportions of sand and water to cement (S/C and W/C) shall
be selected and controlled by the manufacturer in order to achieve compliance with this QCP. The methods of determination of the ratios S/C and W/C shall be specified by the manufacturer.

Doc Title Doc. No.

Date Sep-15
STANDARD QUALITY CONTRROL PLAN FOR W-P-QCP-011
DUCTILE IRON FITTINGS Rev 1
Page 16/16