Typical PE Raw Material and PE Pipe Specification
These specifications are for HDPE pipes of diameters 20 mm to 400 mm used for water distribution networks.
RAW MATERIAL
Raw material used to manufacture the PE pipes shall be virgin pre compounded black as well as natural PE 100 grade as per ISO4427:2007, IS:4984:1995. The carbon black content in the material shall be within 2.5 ±0.5% and the dispersion of carbon black shall be satisfactory when tested as per IS 2530.
The pipes shall generally meet the specification as per latest revisions and amendment of IS: 4984 and IS: 7328 unless otherwise mentioned. The PE100 Black compound proposed to be used for manufacturing of the pipes should also comply with the following norms certified by the raw material manufacturer from an independent 3rd party laboratory like Exova (formerly Bodycote), KIWA etc which should be submitted by the pipe supplier.
The raw material should have certification as per ISO 9080:2003 and ISO 12162 by an independent international testing laboratory for having passed 10,000 hour long term hydrostatic strength (LTHS) test extrapolated to 50 years to show that the resin has a minimum MRS of over 10MPa. Certification as per ISO 13477:2008 - Determination of resistance to rapid crack propagation (RCP) - Small-scale steady-state test (S4 test). The certification shall be latest and validation should not exceed more than 3 years. The material should also meet requirement resin as per IS: 4984.
The raw material used shall be from the positive list of the PE100+ Association, which is available from www.pe100plus.net
The raw material should meet the requirements of BS 6920-1:2000, i.e., Water Regulatory Advisory Scheme (WRAS) Approval for 'suitability of non- metallic products for use in contact with water intended for human consumption with regard to their effect on the quality of water'. The material should also meet requirement of IS: 4984.
Quality assurance certification
Pre-Production Stage Inspection
A certificate of analysis should be obtained from raw material manufacturer for every batch of raw material mentioning Grade name, lot no, quantity, date of manufacturing, MFI, Density, OIT, Carbon black content and dispersion.
Pressure Rating
The pressure rating of HDPE pipes and specials shall be of PN XXXX confirming to clause 3.3 of IS 4984 or as per the requirement of the buyer.
Density and MFR
The specified base density shall be between 940.0 kg/ m³ and 958.4 kg/ m³ (both inclusive) when determined at 27°C according to procedure prescribed in IS 7328 The value of the density shall also not differ from the nominal value by more than 3 kg/ m³ as per 5.2.1.1 of IS 7328. The MFR of the material shall be between 0.2g/10 min to 1.10g/10 min (both inclusive) when tested at 190°C with nominal load of 5 Kg as determined by method prescribed in IS: 2530. The MFR of the material shall also be within ± 20 percent of the value declared by the manufacturer.
Reworked material
As per the provision clause 5.4 of IS4984:1995, addition of not more than 10 percent of the manufacturer's own reworked material resulting from the manufacture of pipes is permissible. No other reworked or recycled material shall be used. The material to be used shall be clean and should be derived from the same resin as used for the relevant production.
Dimensions
The pipes up to and including diameters 110mm shall be supplied in coils of minimum 100m length. The coils shall be as per clause 6.5 of IS4984:1995. Pipe beyond 110mm shall be supplied in straight lengths of minimum 6/12 meter.
The internal diameter, wall thickness, length and dimension tolerances of pipes shall be as per relevant tables of of IS: 4984:1995 for different class of pipes. Pipes shall be of uniform thickness throughout its length.
Performance requirements
The pipe supplied should have passed the acceptance tests as per clause 9.2 of IS4984:1995. The manufacturer should provide the test certificates for the tests conducted, as required in clause 9.2 of IS: 4984 -1995 along with the supply of pipes. These tests are to be performed in the in-house laboratory of the pipe manufacturer.
Marking
As per the provisions of clause 10 of IS4984:1995, each straight length of the pipe shall be clearly marked in indelible ink/ paint every meter and for coils at every 5m the following information:
The manufacturer's name and/ trade mark
Designation of the pipe as per IS (PE 100 & PN10)
Lot number/ Batch number
Project Name XXXXXXXXXXXXXXX(every 0.5 mtr in coil/lengths)
BIS License
The pipe manufacturer for the project has to have a valid BIS license for the kind of pipes required for this project. The bidders shall include this valid license along with their bid. Bid without these licenses may be treated as not valid.
Third Party Inspection
The pipes shall be accepted successful after the third party inspection by SGS, RITES or any other agency authorized by Project Manager.
Project Manager reserves the rights to adopt following inspection plan partly or fully during execution of supply order.
Pre-Production Inspection :Checking of incoming material documents by way of invoices and bill of landing / RG 1 stock, Physical verification of material with batch nos.,
Typical PE Raw Material and PE Pipe Specification
During Production Inspection : 24X7 production inspection, withdrawal of raw material samples for inspection, post production / field inspection and drawing of pipes samples from field sufficient lab testing including counter samples.
Pipe manufacturer will give a warranty for 5 years against manufacturing defects. In case of any dispute the buyer will have a right to get the failed sample tested at an independent laboratory or the declared raw material manufacturer.
Site Stage Inspection
Project manager is authorized to withdraw samples of pipes from site and send for independent recognized testing laboratories.