As 1281-2001 Cement Mortar Lining

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Title: AS 1281-2001 Cement mortar lining of steel pipes and fittings
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AS 1281
fittings
Australian Standard™
Cement mortar lining of steel pipes and

AS 1281—2001
This Australian Standard was prepared by Committee WS-009, Rolled and Welded
Steel Pipes. It was approved on behalf of the Council of Standards Australia on
16 March 2001 and published on 21 March 2001.
The following interests are represented on Committee WS-009:

Australian Chamber of Commerce and Industry
Australian Industry Group
New Zealand Manufacturers Federation
Water Services Association of Australia
Department of Land and Water Conservation
Keeping Standards up-to-date

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NSW 2001.
This Standard was issued in draft form for comment as DR 99526.

AS 1281—2001
Australian Standard™
Cement mortar lining of steel pipes and

fittings
Originated as AS CA41—1965.
Previous edition AS 1281—1993.
Fourth edition 2001.
COPYRIGHT
© Standards Australia International
All rights are reserved. No part of this work may be reproduced or copied in any form or by any
means, electronic or mechanical, including photocopying, without the written permission of the
publisher.
Published by Standards Australia International Ltd
GPO Box 5420, Sydney, NSW 2001, Australia
ISBN 0 7337 3820 6
AS 1281—2001 2
PREFACE
This Standard was prepared by the Standards Australia Committee WS-009, Rolled and
Welded Steel Pipes, to supersede AS 1281—1993.
This edition differs from the 1993 edition in the following respects:
(a) The specification for aggregates has been changed to take account of changes made to
AS 2758.1.
(b) The specification for cement has been changed to take account of changes made to
AS 3972.
(c) Requirements for recycled water quality have been detailed within this Standard.
(d) Requirements for admixtures specified for use in hand lining application has been
changed.
(e) Changes have been made to the specification of defects.
(f) The minimum curing temperature has been reduced to 0°C.
(g) Set back lengths have been updated.

(h) The methods for demonstrating compliance with the Standard have been updated.
Test frequencies have been included.
The objective of this Standard is to provide the purchasers, suppliers and manufacturers of
cement-lined steel pipe with a specification for minimum requirements, and means for
demonstrating compliance with this Standard.
This Standard does not apply to the in situ cement mortar lining of pipelines and details of
admixtures are not provided.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendices to which they apply. A ‘normative’ appendix is an integral
part of a Standard, whereas an ‘informative’ appendix is for information and guidance only.
3 AS 1281—2001
CONTENTS
Page
1 SCOPE ........................................................................................................................... 4
2 REFERENCED DOCUMENTS ..................................................................................... 4
3 DEFINITIONS ............................................................................................................... 5
4 MATERIALS ................................................................................................................. 6
5 PROPORTIONING OF MATERIALS........................................................................... 7
6 PREPARATION OF STEEL SURFACE ....................................................................... 7
7 APPLICATION OF MORTAR ...................................................................................... 7
8 THICKNESS OF LINING.............................................................................................. 9
9 SURFACE QUALITY/WORKMANSHIP ..................................................................... 9
10 CEMENT MORTAR ENDS......................................................................................... 10

11 CURING OF LINING .................................................................................................. 11
12 APPLICATION OF CURING COMPOUNDS AND SEAL COATS ........................... 13
13 EFFECT OF CEMENT MORTAR LINING ON WATER QUALITY ......................... 13
14 HANDLING AND STORING OF PIPES..................................................................... 13
APPENDICES
A PURCHASING GUIDELINES .................................................................................. 14
B MEANS OF DEMONSTRATING COMPLIANCE WITH THIS STANDARD ........ 15
C TABLE OF NOMINAL SIZE AND CORRESPONDING OUTSIDE DIAMETER .. 18
AS 1281—2001 4
STANDARDS AUSTRALIA
Australian Standard
Cement mortar lining of steel pipes and fittings
1 SCOPE
This Standard specifies requirements for the cement mortar lining of steel pipes and fittings
of 100 mm diameter and greater, by centrifugal, spray or hand application methods, prior to
their installation in pipelines. These pipelines are used for the conveyance of water intended
for human consumption or for the conveyance of wastewater or process water.
NOTES:
1 Guidelines to purchasers on information that should be supplied by the purchaser and those
variables that should or may be agreed upon at the time of enquiry or order are given in
Appendix A.
2 Alternative methods for demonstrating compliance with this Standard are given in
Appendix B.
2 REFERENCED DOCUMENTS
The following documents are referred to in this Standard:
AS
1012 Methods of testing concrete
1012.3.1 Method 3.1: Determination of the properties related to the consistency of
concrete — Slump test
1012.20 Method 20: Determination of chloride and sulfate in hardened concrete and
concrete aggregates
1141 Methods for sampling and testing aggregates
1141.5 Part 5: Bulk density and water absorption of fine aggregate
1199 Sampling procedures and tables for inspection by attributes
1379 The specification and manufacture of concrete
1627 Metal finishing — Preparation and pre-treatment of surfaces
1627.9 Part 9: Pictorial surface preparation standards for painting steel surfaces
2758 Aggregates and rock for engineering purposes
2758.1 Part 1: Concrete aggregates
3799 Liquid membrane-forming curing compounds for concrete
3855 Suitability of plumbing and water distribution products for contact with potable
water
3972 Portland and blended cements
AS/NZS
3500 National Plumbing and Drainage Code
3500.0 Part 0: Glossary of Terms
4020 Products for use in contact with drinking water
© Standards Australia www.standards.com.au

5 AS 1281—2001
SAI
HB18 Guidelines for third-party certification and accreditation
HB18.28 Guide 28: General rules for a model third-party certification system for
products
ISO
2859 Sampling procedures for inspection by attributes
2859-1 Part 1: Sampling plans indexed by acceptable quality level (AQL) for lot-
by-lot inspection
3951 Sampling procedures and charts for inspection by variables for percent
nonconforming
ASTM
D4541 Pull-off strength for coatings using portable adhesion testers
APHA*
2540 Total solids
4500 Chloride
4500 Sulphate
3111 Metals by flame atomic absorption spectrometry

5520 Oil and grease
4500 pH value
3 DEFINITIONS
For the purpose of this Standard, the definitions in AS/NZS 3500.0 and those below apply.
3.1 Admixture
A material other than water, aggregates and cementitious materials used as an ingredient in
mortar, and added to the batch in controlled amounts immediately before or during its
mixing, to produce some desired modification to the properties of the mortar.
3.2 Centrifugal application
A process by which mortar is compacted by high-speed spinning about its longitudinal axis.
3.3 Curing
The development of mortar strength under conditions that inhibit shrinkage and cracking,
by retention of moisture in the mortar.
3.4 Curing compound
A coating applied to cover the cement mortar lining surface for the purpose of water
retention that is, to enable water curing of the cement mortar.
3.5 Fitting
Anything fitted in a pipeline for jointing, or changing the direction or internal diameter of
the pipeline.
* American public health association, Standard methods for the examination of water and waste
water (20 th edition)
www.standards.com.au © Standards Australia

AS 1281—2001 6
3.6 Laitance
A chalky surface layer composed of finer fractions of mortar, which can readily be removed
from the lining by scraping with a blade after the lining has cured. (This does not include
the cement-rich layer, which is an integral part of the lining and cannot be easily removed.)
3.7 Lining
A protective coating applied to the internal surface of a pipe or fitting.
3.8 Mortar
Cement mortar consisting of cement, inert aggregates and water.
3.9 Outside diameter
The specified outside diameter of the uncoated pipe or fitting, expressed in millimetres.
3.10 Seal coat
A coating applied to cover the cement mortar lining surface for the purpose of reducing
leaching of cementitious products during service.
3.11 Spray application
A process by which mortar is applied either—

(a) by the use of a centrally positioned spinning head applicator that distributes a fine
spray of mortar around the circumference as the head is moved; or
(b) by pneumatically spraying the lining onto the steel surface.
4 MATERIALS
4.1 Aggregates
Aggregates used for the manufacture of the mortar shall be normal weight, fine aggregate
complying with AS 2758.1. The aggregates shall also meet the requirements specified for
the most severe exposure classification, that is classification C.
NOTE: Other aggregate material may be used by agreement between the purchaser and the
manufacturer, provided that the resultant lining complies in all other respects with this Standard
(see Appendix A).
4.2 Cement
Unless otherwise specified, Type GP, Type GB or Type SR cement supplied in accordance
with AS 3972 shall be used and manufactured in accordance with AS 1379.
NOTES:
1 Other cements, and an upper limit on the mineral additions in the cement may be applied, as
agreed between the purchaser and the manufacturer (see Appendix A).
2 For applications where the water being conveyed has a sulphate content in excess of
500mg/L, Type SR cement should be used.
3 In certain environments, e.g. in aggressive sewage where hydrogen sulphide (H 2 S) is present,
an alternative cement type or alternative corrosion protection may be required.
4.3 Water
Water used for the manufacture of the mortar and curing of the lining shall be taken from a
potable water supply or from recycled water. Where recycled water is used, the water shall
comply with Table 1.

7 AS 1281—2001
TABLE 1
ACCEPTABLE QUALITY OF RECYCLED WATER
Water quality indicator Limit on concentration Test method

Total dissolved solids ≤ 3000 mg/L APHA 2540
−
Chlorine, Cl ≤ 500 mg/L APHA 4500
Sulphate, SO4 2−
≤ 800 mg/L APHA 4500
Sodium, Na +
≤ 300 mg/L APHA 3111
Oil and Grease ≤ 50 mg/L APHA 5520
PH > 5.0 APHA 4500
4.4 Admixtures
For hand-applied linings, admixtures shall be used to improve bonding and to reduce the
water:cement ratio. Chloride-based admixtures shall not be used. Details of admixtures
shall be made available to the purchaser on request.
4.5 Cement mortar

The cured cement mortar shall have a chloride content less than or equal to 0.8 kg/m3 when
tested in accordance with AS 1012.20.
5 PROPORTIONING OF MATERIALS
5.1 Measurement and mixing of materials
The proportions of aggregate and cement shall be measured by mass.
5.2 Aggregate:cement ratio
The aggregate:cement ratio after mixing shall not exceed 2:1 by mass for pipe outside
diameters up to and including 762 mm, and shall not exceed 3:1 by mass for larger pipe
diameters for the purposes of the ratio calculation. The aggregate mass content shall be
based on a saturated surface dry condition in accordance with AS 1141.5.
5.3 Water:cement ratio
The water:cement ratio should be as low as possible for the production of the specified
lining and applicable to the method of application.
NOTE: No limit has been set for the water:cement ratio because the optimum ratio depends on the
mix proportions, the diameter of the pipe to be lined, and the method of applying the mortar to
the pipe. The water:cement ratio in mortar linings after centrifugal application is usually in the
range of 0.25 to 0.40:1.0.
6 PREPARATION OF STEEL SURFACE

At the time of application of the mortar, the surface of the pipe or fitting shall be free of
loose rust, loose millscale, dirt, debris, oil, grease and other detrimental material. If
chemicals deleterious to steel or cement mortar are used to clean the steel surface, such
chemicals shall be removed at the completion of the cleaning process.
7 APPLICATION OF MORTAR
7.1 Method of application
The mortar shall be applied by centrifugal application for pipes. Hand application, spray
application or centrifugal application or a combination of these shall be used for fittings.

AS 1281—2001 8
7.2 Centrifugal application

Centrifugal application shall be used for pipes and pipe sections from which fittings may be
made. The mortar shall be applied by a high-speed spinning centrifugal process. The
consistency of the mortar mix and the speed and duration of the spinning shall be such that
the segregation of the aggregates from the cement is minimized. The filling procedure shall
be such that discrete layering of the mortar is avoided.
After the mortar has been evenly distributed, the pipe shall be spun at high-speed to
produce a dense lining with a smooth surface and a minimum of shrinkage. Water
centrifuged from the mortar shall be removed.
NOTE: When lining steel pipe, the straightness of the pipe will have a significant influence on the
ability to achieve the required lining thickness.
7.3 Spray application
Spray application may be used for fittings and repairs. The procedure shall be such that
discrete layering of the mortar is avoided.
7.4 Hand application
7.4.1 General
Hand application shall be used only for fittings and repairs. The lining shall be compacted
and finished to a surface complying with Clause 9.
Admixtures shall be used in the mortar to improve its adhesion to steel and existing mortar,
and to reduce the water:cement ratio.
The suitability of mortar plus admixtures shall be determined by a type test for adhesion to
steel and cured mortar, and water:cement ratio, in accordance with Clauses 7.4.2 and 7.4.3,
respectively.
7.4.2 Adhesion to steel and cured mortar
A typical mortar of sand, cement, water and admixtures shall be prepared and hand applied
to both bare steel (with intact millscale, shown as surface A in AS 1627.9) and to cured
mortar (at least 14 days old). After water-curing for 4 days, as specified in Clause 11.2, the
samples shall be left to dry in air at an ambient temperature of 23 ±2°C for 14 days and then
immersed in lime-saturated potable water for 28 days. After immersion, the samples shall
be allowed to dry for one to three days prior to testing. The adhesion of the mortar to bare
steel and to cured mortar shall then be determined in accordance with ASTM D4541. The
mortar to be tested shall be scored, or separated by an alternative means from adjacent
mortar, during testing. The average bond strength of three samples prepared for mortar to
steel adhesion testing and three samples prepared for mortar to mortar testing shall each be
greater than or equal to 0.4 MPa.
7.4.3 Water:cement ratio
A control mortar of 2 parts sand and 1 part cement and water shall be made so that the
slump is 60 ±10 mm when tested in accordance with AS 1012.3.1. The mortar to be tested
shall be made of 2 parts of the same sand and 1 part of the same cement, together with
admixtures and water such that the total water content is equal to no more than 80% of the
water that was added to the control mortar. The test mortar (with admixtures) shall have a
slump equal to or greater than the slump of the control sample when tested in accordance
with AS 1012.3.1.

9 AS 1281—2001
7.5 Reinforcement
Where reinforcement is required and tack or spot welding is to be undertaken, the carbon
equivalent (CE) of the steel pipe shall be less than or equal to 0.40, when calculated using
the following equation:
% Mn % Cr + % Mo + % V % Ni + % Cu
CE = % C + + +
6 5 15
NOTE: Reinforcement in the form of wire mesh secured by frequent tack or spot welding may be
required in specific regions on fittings or on large diameter pipes (typically above 1829 mm
outside diameter) and may be specified by the purchaser (see Appendix A).
8 THICKNESS OF LINING
For pipes and fittings up to and including 1829 mm outside diameter, the thickness of the
mortar lining shall be as given in Table 2. The mortar thickness shall comply with the
requirements of Table 2, at all points in each pipe and fitting. The thickness may be
measured in the green state or when cured. In the green state a pin gauge shall be used.
After curing, an eddy current thickness meter shall be used for non-destructive thickness
measurement.
NOTE: For nominal sizes and applicable outside diameters, see Appendix C.
For pipes and fittings exceeding 1829 mm outside diameter, the thickness of the lining shall
be by agreement between the purchaser and the manufacturer.
NOTE: For purchasing guideline, see Appendix A.
TABLE 2
LINING THICKNESS
millimetres
Pipe size
Lining thickness Tolerance
(outside diameter)
≥100 ≤273 9 ±3
>273 ≤762 12 ±4
>762 ≤1 219 16 ±4
>1 219 ≤1 829 19 ±4
9 SURFACE QUALITY/WORKMANSHIP
9.1 General
The lining, when completed, shall have a smooth surface free from major surface
irregularities. Projections exceeding 4 mm, as measured from the general surface of the
lining, shall be removed either by trowelling before the mortar has set, or by grinding after
the lining has cured.
The thickness of the laitance shall not exceed 10% of the cement mortar lining thickness.
9.2 Defects
The following defects shall be repaired in accordance with Clause 9.3:
(a) Voids, sand and clay pockets, blisters, areas that are thin and cracks of width such
that a commercial metal feeler gauge 2.0 mm thick can be inserted to a depth of
greater than half the thickness of the lining. Lining that results in a step between
adjacent sections of lining in excess of 2.0 mm (see Figure 1).

AS 1281—2001 10
NOTE: Cracks up to 2 mm in width are acceptable for pipes conveying potable water. Such
cracks are not detrimental in service and need not be repaired, as they will close and heal
when immersed in water (see Clause 14.2).
(b) For pipelines carrying wastewater or saline water, the maximum tolerable crack size
and allowable step displacement shall be by agreement between the manufacturer and
the purchaser.
NOTE: For purchasing guidelines, see Appendix A.
9.3 Repairs
Defects shall be repaired as soon as practicable. Cement mortar with an aggregate:cement
ratio not greater than that used on the pipe or fitting shall be spray-applied or hand-applied
and trowelled to achieve the specified thickness.
Admixtures in accordance with Clauses 4.4, and applied in accordance with Clause 7.4,
shall be used to reduce the water:cement ratio and improve the adhesion of the repair mortar
to steel and the existing cured mortar.
Other methods of repair shall be by agreement between the purchaser and the manufacturer.
FIGURE 1 STEP CAUSED BY CRACKING OF A CEMENT MORTAR LINING
10 CEMENT MORTAR ENDS

Cement mortar linings shall be terminated at a set distance from the pipe ends, to allow for
the required deflection of the joints. The setback lengths are given in Table 3 for pipes up to
1829 mm outside diameter.
The setback lengths for pipes of outside diameter greater than 1829 mm shall be subject to
agreement between the manufacturer and the purchaser.
The cement mortar lining in pipes of 600 mm outside diameter and greater shall be finished
with an undercut angle range of 10° to 30°, to assist in keying in of the cement mortar joint
reinstatement, unless otherwise agreed between the purchaser and manufacturer.

11 AS 1281—2001
11 CURING OF LINING
11.1 Methods of curing
All linings shall be water- or steam-cured in accordance with either Clause 11.2 or
Clause 11.3, unless a seal coat or curing compound is applied to uncured mortar, in
accordance with Clause 12.
11.2 Water curing
The linings of pipes and fittings shall be water-cured as follows:
(a) Immediately after the application of the lining to the pipe or fitting, the ends of the
pipe or fitting shall be sealed to prevent the circulation of air and loss of water
vapour.
(b) The end seals shall be maintained for a minimum period of four days measured from
the time of application of the mortar lining. If the end covers become dislodged or
damaged, the lining shall be sprayed with water (as specified in Clause 4.3) and the
ends shall be resealed.
(c) During the first two days of the curing period the temperature of the cement mortar
shall not fall below 0°C.
NOTE: The pipes and fittings may be despatched at any time after the four-day curing period.
11.3 Steam curing
The linings of pipes and fittings shall be steam-cured as follows:
(a) Immediately after the application of the lining, the ends of the pipe or fitting shall be
sealed to prevent the circulation of air and loss of water vapour.
(b) After standing for not less than 2 h, steam shall be injected into the pipe or fitting so
as to raise the inside temperature at a rate not exceeding 30°C/h until the temperature
of the surface of the lining is within the range 55°C to 70°C.
(c) Steaming shall be continued for a further 6 h, the temperature of the lining being
maintained within the range specified above.
(d) The steam shall then be shut off, and the pipe or fitting with the ends still sealed shall
be held for one day commencing from the time the temperature of the lining has
fallen to ambient air temperature.
(e) During the complete curing cycle, the temperature of the lining of a representative
number of pipes or fittings shall be recorded by a suitable instrument.
NOTE: For pipelines intended for wastewater applications, alternative curing methods may be
used by agreement between the purchaser and the manufacturer (see Appendix A).

© Standards Australia
AS 1281—2001
TABLE 3
SETBACK LENGTHS AT PIPE ENDS
millimetres
Joint type
Plain ends
Plain ends
internally and Slip-in externally Slip-in internally and
Outside Rubber ring joint externally Ball and socket
externally welded only externally welded
diameter welded only
welded
Socket Spigot Both ends Both ends Socket Spigot Socket Spigot Socket Spigot
12
±3 ±3 +1, −0 +0, −3 ±3 ±3 ±3 ±3 ±3 ±3
≥100 ≤324 145 3 0 NA 30 3 NA NA NA NA
>324 ≤508 145 3 0 NA 45 3 NA NA NA NA
>508 ≤762 145 3 0 35 70 3 NA NA NA NA
>762 ≤1 118 145 3 0 50 90 3 110 50 130 50
>1 118 ≤1 321 145 3 NA 50 115 3 140 85 160 50
>1 321 ≤1 626 145 3 NA 50 NA NA 140 85 200 50
>1 626 ≤1 829 NA NA NA 50 NA NA NA NA 200 85
NA = Not applicable
www.standards.com.au
13 AS 1281—2001
12 APPLICATION OF CURING COMPOUNDS AND SEAL COATS

When a curing compound is applied to fresh uncured mortar no end sealing shall be
required for water curing (see Clause 11.2) provided the water retention efficiency index of
the curing compound is not less than 90% when tested in accordance with AS 3799.
The application of a seal coat or curing compound shall be by agreement between the
purchaser and the manufacturer.
13 EFFECT OF CEMENT MORTAR LINING ON WATER QUALITY

Cement mortar lining, for use in contact with water intended for human consumption, shall
comply with the requirements of AS 3855 or AS/NZS 4020. Tests undertaken on the
applied lining shall include any admixtures, seal coats and curing compounds used.
14 HANDLING AND STORING OF PIPES

14.1 Lifting and handling
Pipes and fittings lined with mortar shall be lifted and handled in a manner that will avoid
permanent distortion of the pipes or fittings and damage to the lining.
14.2 Storing and transporting

Pipes and fittings lined with mortar shall be supported both in storage and during transport
in a manner that will avoid permanent distortion of the pipe and damage to the lining.
NOTE: Where pipes are stored for long periods (i.e. typically longer than three months) or in very
hot or dry climates, shrinkage cracking of the lining in excess of 2 mm may occur. The purchaser
should advise the manufacturer if pipes are to be stored for an extended period (see Appendix A).

AS 1281—2001 14
APPENDIX A
PURCHASING GUIDELINES
(Informative)
A1 GENERAL
Australian Standards are intended to include the technical provisions necessary for the
supply of products referred to in the particular Standard, but do not purport to contain all
the necessary provisions of a contract.
In a number of cases the purchaser is either asked to state specific requirements or is given
a choice of optional requirements. These are contractual matters to be agreed between the
purchaser and the manufacturer.
This Appendix contains advice and recommendations on the information to be supplied by
the purchaser at the time of enquiry or order and by the manufacturer after the order has
been placed. Its aims are to avoid misunderstandings and to result in the purchaser
receiving satisfactory products and service.
A2 INFORMATION TO BE SUPPLIED BY THE PURCHASER

The purchaser should supply the following information:
(a) The nominal pipe size or outside diameter and number of pipes or fittings to be lined.
(b) Requirements for reinforcement, if any (see Clause 7.5).
(c) Whether pipes will be stored for an extended period (typically longer than three
months) prior to installation (see Clause 14.2).
(d) Whether pipes will be used to convey water intended for drinking purposes. (If not,
the water analysis should be supplied.)
A3 MATTERS TO BE DECIDED BY AGREEMENT

The purchaser and the manufacturer should agree on the following matters, where
applicable:
(a) Details of aggregates to be used, if other than specified in Clause 4.1.
(b) The type of cement to be used, if other than specified and if there is a limit on mineral
additions to the cement (see Clause 4.2).
(c) The thickness of the lining for pipes and fittings of outside diameter greater than
1829 mm (see Clause 8).
(d) The maximum tolerable crack size and allowable step for wastewater or saline water
pipelines (see Clause 9.2).
(e) If repairs are to be made by an alternative means (see Clause 9.3).
(f) Details of requirements for setback lengths at pipe ends, if different from Table 3 (see
Clause 10).
(g) Whether a seal coat or curing compound is required to be applied to the finished
mortar lining (see Clause 12 and 13).
(h) The required curing period for wastewater pipeline applications.
A4 INFORMATION TO BE SUPPLIED BY THE MANUFACTURER

When requested by the purchaser, the manufacturer shall supply details of admixture(s)
used.

15 AS 1281—2001
APPENDIX B
MEANS OF DEMONSTRATING COMPLIANCE WITH THIS STANDARD
(Normative)
B1 SCOPE
This Appendix sets out two means by which compliance with this Standard shall be
demonstrated by a manufacturer.
(a) The use of a product certification scheme.
(b) The use of a minimum sampling and testing frequency plan.
B2 RELEVANCE
The long-term performance of pipeline systems is critical to the operating efficiency of
water agencies in terms of operating licences and customer contracts. The long-term
performance of plumbing systems is similarly critical to the durability of building
infrastructure, protection of public health and safety and protection of the environment.
B3 DEFINITIONS
B3.1 Acceptable quality level (AQL)
When a continuous series of lots or batches is considered, the quality level which for the
purpose of sampling inspection is the limit of a satisfactory process average (see
ISO 2859-1 and ISO 3951)
NOTE: The designation of an AQL does not imply that a manufacturer has the right to knowingly
supply any non-conforming unit of product.
B3.2 Batch
A defined quantity of material/product produced under uniform conditions, which is defined
and identified by the material/product producer.
B3.3 Batch release test (BRT)
A test performed on a sample from the batch, to confirm conformance to the requirements
of this Standard.
B3.4 Inspection level
The relationship between the lot or batch size and the sample size (see ISO 2859-1).
B3.5 Lot
A clearly identifiable sub-division of a batch for inspection purposes.
B3.6 Material batch
A clearly identifiable quantity of a particular material.
B3.7 Production batch
A clearly identifiable collection of units, manufactured consecutively or continuously under
the same conditions, using material to the same specification.
B3.8 Sample
One or more units of product drawn from a batch or lot selected at random with regard to
quality.
NOTE: The number of units of product in the sample is the sample size.

AS 1281—2001 16
B3.9 Sampling plan

A specific plan, which gives the number of samples and the frequency of inspection or
testing.
B3.10 Type test (TT)
A test performed on a sample to confirm that a new design, material, component, joint or
assembly conforms to the requirements of the relevant Standard before any batches can be
released.
B4 PRODUCT CERTIFICATION
The purpose of product certification is to provide independent assurance of the claim by the
manufacturer that products comply with this Standard.
The certification scheme shall meet the criteria described in HB 18.28/SANZ HB 18.28
(ISO/IEC Guide 28) in that, as well as full type testing from independently sampled
production and subsequent verification of conformance, it requires the manufacturer to
maintain effective planning to control production.
The certification scheme serves to indicate that the products consistently conform to the
requirements of this Standard.

Product certification shall be conducted by a certification body accredited by the Joint
Accreditation System for Australia and New Zealand (JAS-ANZ) or by another certification
body that is acceptable to JAS-ANZ.
The frequency of the sampling and testing plan as detailed in Paragraph B5 shall be used by
the certifying body for product compliance auditing. However, where the manufacturer can
demonstrate adequate process control to the certifying body, the frequency of sampling and
testing nominated in the manufacturer’s quality plan and/or documented procedures shall
take precedence for the purpose of product certification.
B5 MINIMUM SAMPLING AND TESTING FREQUENCY PLAN

B5.1 General
Table B1 sets out the minimum sampling and testing frequency plan for a manufacturer to
demonstrate compliance of product(s) to this Standard.
B5.2 Retesting
In the event of a test failure, the products manufactured since the previous test(s)
conforming to the requirements outlined in Table B1 shall be quarantined as a batch. A
further set of samples shall be selected randomly from the quarantined batch using a
sampling plan to AS 1199 for an acceptable quality level (AQL) of 2.5 and an inspection
level of S3, unless otherwise specified. If the retest requirements are met, the batch may be
released and compliance with this Standard for the quarantined batch may be claimed.
Should a failure on retesting occur, then the quarantined batch shall be rejected and claims
and/or marking indicating compliance to this Standard shall be suspended until the cause of
the failure has been identified and corrected.
B5.3 Rejection after retest
In the event of a quarantined batch being rejected after retesting, it may be subjected to
100% testing for the failed requirement(s), and only those items found to comply may be
claimed and/or marked as complying with this Standard.

17 AS 1281—2001
TABLE B1
TYPICAL MINIMUM SAMPLING AND TESTING FREQUENCY PLAN
Characteristics Clause Requirement Test method Frequency
TYPE TESTS (TT)

Cement 4.2 Certificate of AS 3972 Annually and at a change of
compliance from the cement or supplier
supplier
Aggregates 4.1 Certificate of AS 2758.1 Annually and at a change of
compliance from the aggregate or supplier
supplier
Chloride content 4.5 ≤0.8 kg/m3 AS 1012.20 Annually and at any change
in cement, aggregate and/or
water supply
Admixture type tests 7.4.2 & See Clauses 7.4.2 & ASTM D 4541 and Five yearly and at a change
7.4.3 7.4.3 AS 1012.3.1 in the admixture
Laitance thickness 9.1 ≤ 10% of the lining By any convenient Annually and at a change in
thickness measurement method cement and/or aggregate
supply
Effect on water 13 Suitable for contact AS/NZS 4020 or Five yearly and at a change
with drinking water AS 3855 in cement and/or aggregate
supply
BATCH RELEASE TESTS (BRT)

Lining thickness 8 See Table 2 Pin gauge or eddy Twice per shift for pipe and
current measurement every fitting
Surface quality/ 9 See Clauses 10.1 & Visual inspection Visual inspection of every
workmanship 10.2 pipe and fitting
Set back length 10 See Table 3 By any convenient Once from the first 10 pipes
measurement method. and fittings in each
production run
Recycled water 4.3 See Table 1 See Table 1 To be determined based on
statistical analysis (see Note)
NOTE: The test frequency for recycled water needs to be determined based on the results obtained. For example, if the
system is well controlled, and monthly tests indicate water chemistries well below the specified limits, then the
frequency of testing could be progressively increased to 6 monthly. Alternatively, if the water chemistry of the water is
close to the limits, then the frequency of testing might need to be weekly.

AS 1281—2001 18
APPENDIX C
TABLE OF NOMINAL
SIZE AND CORRESPONDING
OUTSIDE DIAMETER
(Informative)
Nominal size Outside diameter

DN mm
100 114
150 168
200 219
250 273
300 324
350 356
400 406
450 457
500 508
600 610
700 711
750 762
800 813
900 914
1 000 1 016
1 200 1 219
1 400 1 422
1 600 1 626
1 800 1 829
2 000 2 032
2 200 2 235

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As 1281-2001 Cement Mortar Lining

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Licensee: Peter Chrystie

Date: 05 Aug 2003

Cement mortar lining of steel pipes and

The following interests are represented on Committee WS-009:

Keeping Standards up-to-date

This Standard was issued in draft form for comment as DR 99526.

Cement mortar lining of steel pipes and

(g) Set back lengths have been updated.

10 CEMENT MORTAR ENDS......................................................................................... 10

© Standards Australia www.standards.com.au

3111 Metals by flame atomic absorption spectrometry

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A process by which mortar is applied either—

© Standards Australia www.standards.com.au

Water quality indicator Limit on concentration Test method

4.5 Cement mortar

6 PREPARATION OF STEEL SURFACE

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7.2 Centrifugal application

© Standards Australia www.standards.com.au

www.standards.com.au © Standards Australia

FIGURE 1 STEP CAUSED BY CRACKING OF A CEMENT MORTAR LINING

10 CEMENT MORTAR ENDS

© Standards Australia www.standards.com.au

www.standards.com.au © Standards Australia

12 APPLICATION OF CURING COMPOUNDS AND SEAL COATS

13 EFFECT OF CEMENT MORTAR LINING ON WATER QUALITY

14 HANDLING AND STORING OF PIPES

14.2 Storing and transporting

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A2 INFORMATION TO BE SUPPLIED BY THE PURCHASER

A3 MATTERS TO BE DECIDED BY AGREEMENT

A4 INFORMATION TO BE SUPPLIED BY THE MANUFACTURER

© Standards Australia www.standards.com.au

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B3.9 Sampling plan

requirements of this Standard.

B5 MINIMUM SAMPLING AND TESTING FREQUENCY PLAN

© Standards Australia www.standards.com.au

Characteristics Clause Requirement Test method Frequency

TYPE TESTS (TT)

BATCH RELEASE TESTS (BRT)

www.standards.com.au © Standards Australia

Nominal size Outside diameter

© Standards Australia www.standards.com.au

GPO Box 5420 Sydney NSW 2001

ISBN 0 7337 3820 6 Printed in Australia

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