WATER SUPPLY RETICULATION

WS.1 GENERAL

The construction of the water supply reticulation shall

comply with the requirements of this Specification and to
fully comply with the latest Requirement, Specification
and Practices of SYABAS or Jabatan Bekalan Air so as to
be able to obtain approval from SYABAS or Jabatan Bekalan
Air.

WS.2 EXCAVATION

WS.2.1 Excavation and backfill shall generally comply with the

section on earthworks in this Specification.

WS.3 Reference to British Standard

This Specification for ductile iron pipes, fittings,

accessories and their joints for water pipelines used in
the Works is based upon the following British Standards
with the latest amendments:-

B.S. EN 545:2002 Ductile iron pipes, fittings,

accessories and their joints for water
pipelines – Requirements and test
methods.

B.S. EN 681-1 Elastomeric seals – Materials

requirements for pipe joint seals used
in water and drainage application Part
1: Vulcanized rubber

B.S. EN 1092-2 Flanges and their joints – Circular

flanges for pipes, valves, fittings and
accessories, PN designated – Part2:
Cast iron flanges.

B.S. 10002-1 Metallic materials – Tensile testing –

Part1: Method of test at ambient
temperature.

B.S. ISO 4016:2000 Hexagon head bolts – Product grade C

B.S. ISO 4034:2000 Hexagon nuts – Product grade C

B.S. ISO 6506-1 Metallic materials – Brinell hardness

test – Part 1: Test method.

B.S. ISO 7091 Plain washers – Normal series – Product

grade C

This Specification shall be interpreted, and all sampling

and testing shall be carried out, in accordance with the
relevant clauses in these Standards.

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W-2
WS.4 DUCTILE IRON PIPES

WS.4.1 The pipes and specials shall be made from ductile iron as
stated in British Standard. The manufacture and testing
of ductile iron pipes shall comply with requirements of
the current edition of British Standard.

WS.4.2 They shall be lined internally with cement mortar. The

ratio by mass of sand to cement shall not exceed 3.5
complying with British Standard EN 197. The 28 dyas
compressive strength shall not be less than 50 MPa. The
thickness of steel plates for pipes and internal lining
shall be as shown in Table 1, unless otherwise stated.

TABLE 1

___________________________________________________________________

Nominal External Class K9 Class 40 Concrete

Diameter Diameter Wall Wall Lining
Thickness Thickness Thickness
DN DE

mm mm mm mm mm
_____________________________________________________________________

100 118 6.0 4.8 4.0

150 170 6.0 5.0 4.0

200 222 6.3 5.4 4.0

250 274 6.8 5.8 4.0

300 326 7.2 6.2 4.0

350 378 7.7 7.0 5.0

400 429 8.1 7.8 5.0

450 480 8.6 5.0

500 532 9.0 5.0

600 635 9.9 5.0

700 738 10.8 6.0

800 842 11.7 6.0

900 945 12.6 6.0

1000 1048 13.5 6.0

__________________________________________________________________

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WS.4.3 All pipes shall be delivered to site with an external
metallic zinc coating with finishing layer of bitumen
coating. The internal of pipes shall be lined with cement
mortar lining.

WS.4.4 The external coating shall be applied in oxide surfaced

pipes after heat treatment. It may also applied on blast
cleaned pipes. Prior to application of zinc, the pipe
surface shall be dry and free form rust or non-adhering
particles or foreign matter such as oil or grease.

WS.4.5 The metallic zinc coating shall cover the external

surface of the pipes and provide a dense, continuous,
uniform layer. It shall be free from such defects as bare
patches or lack of adhesion. The uniformity of coating
shall be checked by visual inspection. The mean mass of
zinc per unit area shall be not less than 130g/m2. The
purity of zinc use shall be at least 99.99%. The
uniformity of the finishing layer shall be checked by
visual inspection. The mean thickness of finishing layer
shall be not less than 70 m. The local minimum thickness
not less than 50 m.

WS.4.6 Standard length for straight pipes of nominal diameters

450 mm and above shall be 9 m while the standard length
for straight pipes of nominal diameters less than 450 mm
shall be 6 m. The maximum variation in length from the
standard lengths shall be kept to the minimum possible
within the normal method of manufacture and shall not
exceed 150 mm.

WS.4.7 Pipe Ends

All pipes shall have a spigot and socket ends.

WS.4.8 Push In Joints

Flexible joint assembled by pushing the spigot through

the gasket in the socket of the mating component.

WS.4.9 Mechanical Flexible Joint

Flexible joint in which sealing is obtained by applying

pressure to gasket by mechanical means e.g a gland.

WS.4.10 Flanged Joints

Flanges shall be made to British Standard. All bolts and

nuts shall be to BS EN 4016 and BS EN 4030.

WS.5 SLUICE VALVES

WS.5.1 Sluice valves up to 12 inch diameter shall be Class I

complying with B.S. 5163 while those over 12 inch (300
mm) diameter shall be of Nominal Pressure of 16 bars
complying with B.S. 5163.
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WS.5.2 Tenderers who propose to supply sluice valves not
entirely in accordance with the above mentioned
British Standards must state in their tender the
difference between the sluice valves they offer and those
which comply with the British Standards.

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WS.5.3 The sluice valves shall have non-rising spindles and
shall be suitable for conveyance of raw or drinking water
in the tropics under the maximum working pressure of 300
feet head of water when fixed in pipelines or in
unsupported terminal positions.

WS.5.4 All valves shall be suitable for operation by one man

under the maximum working pressure. Valves of 375 mm
diameter and over shall have metal seating rings, be
operated by spur gearing and their stems sealed by
stuffing boxes and glands.

WS.5.5 Each sluice valve shall be provided with a cast iron cap
and operating keys. No hand wheels are required.

WS.5.6 Finished Ends of Sluice Valves

Both ends of the sluice valves shall be flanged. The

flanges or valves up to 12 inch diameter shall be
machined and drilled to B.S. 10 : 1962, Table E while
those of valves over 12 inch (300 mm) diameter shall be
machined and drilled to B.S. 4505 : 1969, Table 10/11.

WS.5.7 Internal Finish of Sluice Valves

Smooth and clear internal surfaces are particularly

required and sluice valve having on the inside rough
places or projections which cannot be removed
satisfactorily shall be rejected.

WS.5.8 Testing

All sluice valve up to and including 8 inch diameter

shall be "open end" tested as described in appendix A in
B.S. 5163 and shall show no signs of leakage under these
tests.

WS.5.9 All sluice valves over 8 inch diameter and up to 12 inch

diameter shall be "closed end" tested, as described in
Appendix A in B.S. 5163 while those over 12 inch (300 mm)
shall be "close end" as described in B.S. 5163 : 1974 and
shall show no signs of leakage under those tests.

WS.6 AIR VALVES

WS.6.1 All air valves shall be suitable for operating at a

maximum working pressure of 300 feet head of water and
their bodies and covers, when assembled, shall be capable
of withstanding a hydrostatic test pressure of 600 feet
head of water without any sign of leakage.

WS.6.2 Single Orifice Air Valves

Single orifice air valves shall be suitable for

automatically releasing air that may accumulate in
pipelines under pressure and shall be supplied with air
release nipples of bronze screwed into brass plugs.

WS.6.3 The ball which forms the valve element shall be either
rubber or vulcanite, or covered with rubber or vulcanite

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and shall be of a diameter suitable for operating at
maximum working pressure of 300 feet head of water.

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WS.6.4 Each air valve shall be fitted with a gun-metal isolating
cock of the screwdown pattern at the inlet. The inlet and
outlet of each isolating cock shall be threaded with
British Standard Male Pipe Threads.

WS.6.5 Double Orifice Air Valves

Double orifice air valves shall be of the combined small

and large orifice valve pattern. Each valve shall be
fitted with a screwdown isolating valve with clockwise
rotation of the spindle for closing. It shall be provided
with a 1/2" tapping for draining purposes and the tapping
shall be closed with a brass screw plug. The inlet end
shall be flanged and the flange shall be machined and
drilled to B.S. 10 of 1962, Table E corresponding to the
nominal diameter of the inlet bore.

WS.6.6 The design of the valve shall be such that there is no

possibility of the large orifice being suddenly caught up
in the escaping air stream during the filling of water at
high rates thereby closing the valve prematurely. The
ball for the small orifice shall be rubber or vulcanite,
or covered with rubber or vulcanite while that for the
large orifice shall be vulcanite or covered with
vulcanite. The diameters of the balls in each unit of the
air valve shall be suitable for operating under a maximum
working pressure of 300 feet head of water.

WS.7 FIRE HYDRANTS

WS.7.1 All underground fire hydrants shall comply with B.S.

750 : 1964 "Underground Fire hydrants" including
subsequent additions and amendments thereof and
subject to the deviations and additions specified
herein.

WS.7.2 Underground fire hydrants shall be of the screwed-down

type for use in the Tropics, and shall be fitted with
captive valves. The hydrants shall have bronze spindle,
gun-metal interval valve, and seat ring.

WS.7.3 Fire Hydrant (Pillar Type)

Pillar type double outlet fire hydrants with isolating

valves approved by SYABAS or Jabatan Bekalan Air and Fire
Authorities shall be installed where specifically
required by Fire Authorities.

WS.8 TRANSPORTING OF MATERIALS

All the pipes, specials, fittings, valves, joints and

jointing materials shall be transported to the points
where they are to be laid. Pipes shall be carefully
secured against movements while being transported and
shall be handled in accordance with manufacturer's
recommendation. On no account shall pipes be dropped from
any height or subject to shock. Damaged pipe shall not be
used in the works.

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W-9
WS.9 INSPECTION OF MATERIALS

All pipes, specials, fittings, valves, etc., shall be

carefully inspected for damage which may been caused
during loading, transit and unloading before being
lowered into the trench.

WS.10 VALVE, HYDRANT AND AIR VALVE CHAMBERS

Valve, hydrant and air valve chambers shall be

constructed to the details shown on the Drawings. Pipes
and valves shall be centrally places in chambers unless
otherwise directed by the Engineer. Brickwork shall be
arched over all pipes. Chambers in carriageways shall
have the brickwork corbelled to support precast concrete
covers as directed. The finished levels of any chambers
shall be such that no obstruction shall be offer to any
vehicle, animal or pedestrian. All precast concrete
chambers shall strictly comply with the SYABAS or Jabatan
Bekalan Air's requirements. All steel and chequered plate
covers shall be painted with one coat of bitumastic
paint. All internal surfaces of brickwork wall in
manholes shall be rendered with 1 in thick 1 : 3 cement
sand mortar.

WS.11 STEP IRON

All step iron shall be heavily galvanised malleable iron

castings complying with B.S. 1247 : 1955. Unless
otherwise shown in the Drawings, general purpose pattern
step irons with 4 5/8" tails shall be used in walls 9" or
more in thickness, and rounded bar pattern step irons
shall be used in 4 1/2" walls.

WS.12 MARKER POST

The Contractor shall provide and fix precast Grade "B"

concrete Marker Posts, details of which are shown on the
Drawings, close to the centreline of the pipes at valves,
washouts and other points as directed by the Engineer.
The marker posts shall be set in concrete firmly into the
ground to the depths shown on the Drawings and the
backfilling well rammed.

WS.13 COVER SLABS

Cover slabs shall be of present concrete Grade "B" as

specified, reinforced and constructed as shown in the
Drawings.

WS.14 PIPE LAYING

WS.14.1 Pipes shall be laid only after the trench has been
inspected and approved by the Engineer or his
representative on site. The trench shall be kept
sufficiently dry for making joints.

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WS.14.2 Handling

Pipes shall be gently lowered into the trench by means of

a crane or suitable shear legs and chain blocks with rope
slings. Pipes shall be laid true to invert alignment and
fall. Care shall be exercised to ensure that the barrel
of every pipe is evenly edded throughout.

WS.14.3 Setting Out

Each pipe shall be laid between at least three sights

erected at not more than 50 feet apart. Suitable boring
rods shall be used to set out the profile of the pipe.
WS.14.4 Cleaning

The internal surfaces of all pipes, specials, etc., shall

be cleaned to remove any debris, sticks, rags or other
foreign matter before they are laid and fixed in
position.

WS.14.5 Temporary Stops

Temporary stops for effectively closing the open ends of

the mains shall be used to prevent rainwater from
washing earth and other foreign matter into the mains.
These stops shall be used at all times and shall be moved
forward as the work of laying and jointing progresses.

WS.15 JOINTING OF PIPES

WS.15.1 Spigot and socket ductile iron pipe joints shall be

connected by pushing the spigot through the gasket in the
socket.

Care shall be taken during the operation to ensure that

the concrete lining inside the pipes are not damaged.

WS.15.2 Double Flanged Joints

Flanged joints shall be laid true to line and level

before bolting and on no account shall drifts or podgers
be used in the bolt holes. Flange bolts shall be
carefully and evenly tightened in rotation to ensure even
pressure on the joint ring. The joint ring shall be in
the form of strip ring lying within the bolt circle.

WS.16 HYDRAULIC TESTING OF MAINS

WS.16.1 Testing in Sections

Pipelines shall be tested in sections of about 2,000 feet

(in open ground) and 1,000 feet (along roads) after it
had been laid, jointed and anchored with all
fittings and thrust blocks in position and partly
backfilled. Only sufficient backfilling of the trench to
prevent snaking of the pipes shall be allowed with all
joints and fittings exposed before the satisfactory
completion of tests.

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WS.16.2 Test Ends

The opened ends of the sections to be tested shall be

temporarily sealed with caps. For this purpose "Test
Ends" units consisting of short lengths of cast iron
pipes permanently fitted with capes to the satisfaction
of the Engineer shall be used. These units shall be
jointed to the section of the pipeline to be tested with
standard cast iron couplings which can be easily removed
when the tests had been completed. Each "Test End" shall
be provided with standpipe complete with valve outlet and
pressure gauge to serve as an air relief vent or for use
when filling the pipeline with water. The pressure guage
shall be of sufficient range and tested and the
Contractor shall submit test certificate for the
Engineer's inspection. When one end of the section to be
tested commences at a sluice valve, the valve may be used
in place of the "Test End" unit to close this end of the
section during test. The ends of the pipeline under test
shall be braced with temporary thrust blocks to
withstand the end thrust which develops from water
pressure. Thrust blocks specified for the pipeline shall
be constructed in place and the concrete properly cured
before the tests are carried out. Temporary bracing at
locations of permanent thrust blocks shall not be
permitted as the test includes the testing of permanent
thrust blocks and fitting in addition to the pipeline.

WS.16.3 Water for Testing

The water used in the test shall be of fair quality, free

from sediment and from a source approved by the Engineer.

WS.16.4 Test Preparation

The section of pipeline to be tested shall be filled with

water through the valve in the "Test End" unit at the
lower end of the pipeline. During filling, provision
shall be made for air to escape from all high spots in
the pipeline and from the valve in the upper "Test
End" unit. Where the section of the pipeline is on
a level grade, it may be necessary to drill the main at
several points to ensure the escape of air. Any vent hole
drilled shall be plugged and saddled before the test is
applied. Where the main runs up-hill the pressure gauge
shall be situated at the bottom of the section as
otherwise excessive pressure may be imposed upon the
lower part of the pipeline with a risk of damage to
anchorages designed to withstand the specified test
pressure. Pressure for the test shall be applied by means
of an approved force pump at the highest convenient point
on the main so as to minimise the pressure against which
the pump will have to be operated. The test section shall
be completely filled with water for at least 24 hours
prior to testing to allow for absorption of water into
the pipes and/or jointing materials. The test equipments
shall be sealed against any possible tampering.

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WS.16.5 Pressure Test

Water shall be pumped into the main, raising the

pressure slowly in increments of one bar with pauses of
one minute between each increment. When any appreciable
drop in pressure is noted during one of these pauses the
test shall be stopped until the cause of the pressure
drop has been investigated and rectified. The pipes shall
be tested to the pressure given below :

_________________________________________________
DN Pressure For Pressure For
Pressure/strength Pressure/
test For Class 40 strength test
For Class K9
(Bars) (Bars)
_________________________________________________
_

40 to 300 19 19

350 to 600 19 19

700 to 1000 19
____________________________________________

An engine pump may be used until 10.0 bar, 12.5 bar and
15.0 bar pressure is attained for the respective classes
of pipes and thereafter full test pressure shall be
applied by a hand pump. The pressure/strength test shall
be considered to have been passed when the pressure gauge
shows no reduction from the strength test pressure during
the period of ten minutes after full test pressure had
been attained.

WS.16.6 Leakage Test

The leakage test shall follow the pressure test. The

pressure in the pipes shall be reduced to the valves as
follows :-

_________________________________________________
DN Minimum work Minimum work
Test pressure test pressure
For Class 40 For Class K9
(Bars) (Bars)
_________________________________________________
_

40 to 300 13 13

350 to 600 13 13

700 to 1000 13
____________________________________________

The pressure shall be maintained as constant as possible

for a period of 24 hours by pumping in make-up water if

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 necessary. The leakage test shall be considered to have
passed if the measured quantity of make-up water pumped
into the section of pipeline does not exceed 0.1 litre
per kilometre of pipeline per 24 hours for every
millimetre diameter of pipe and every 30 metres head
pressure.

WS.17 COMPLETION WORKS

WS.17.1 Sterilisation of Water Mains

Mains shall be sterilised after testing, swabbing and

scouring. Chlorine solution shall be applied at the
charging point as the main is being filled and dosing
shall be continued until the main is full and at least 50
milligrammes per litre of free chlorine have been made
available. Chlorine gas shall not be injected direct to
the main from a Cylinder other than through an approved
chlorinator and care shall be taken to ensure that there
is not flow back into the preceeding sections of main.

The treated water shall be left in the main for a period

as directed but not exceeding 24 hours and all valves in
the system shall be operated at least once during this
period. Chlorine residual tests shall then be taken at
the end of the main furthest from the point of injection.

The sterilisation process shall be repeated until the

chlorine residual is not less than 10 milligrammes per
litre.

The Contractor shall dispose of the water chlorine

solution in such a manner as to avoid the pollution of
natural waters and watercourses. The Contractor shall
comply with any directions which the Engineer makes in
respect of such disposal.

WS.17.2 Approval by SYABAS or Jabatan Bekalan Air

The construction of the water supply reticulation shall

comply with the requirements of the SYABAS or Jabatan
Bekalan Air and the Contractor shall be solely
responsible for obtaining SYABAS or Jabatan Bekalan Air's
approval of the completed water supply reticulation and
arranging for any necessary inspections by SYABAS or
Jabatan Bekalan Air during construction or testing.

WS.18 SERVICE CONNECTIONS

WS.18.1 General

The tendered unit price for the supply and laying of the
communication pipe shall be inclusive of thread rolling
the communication pipe, all couplings, excavation and
backfilling. The installation of bends, tees, reducers,
stop-ends, ferrule cock and tapping saddle inclusive of
tapping shall be paid for separately.

WS.18.2 Excavation and Backfilling

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 All excavation and backfilling shall comply with the
section of this Specification on earthworks.

WS.18.3 Pipe

The communication pipe shall be of 3/4 and 1 inch

diameter Stainless steel to SYABAS approval.

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WS.18.4 Coupling, Bend, Tee, Reducer and Stop-End

Coupling, bend, tee, reducer and stop-end shall be

screwed type complying with B.S. 1740 for wrought steel
pipe fittings.

WS.18.5 Tapping Saddle

The tapping saddle shall consist of two sections of cast

iron complying with the relevant requirements of B.S. 143
or 1256 curved to fit the outside diameter of the water
main. They are linked together by galvanised mild steel
bolts. One section of the saddle is drilled and B.S.P
tapped, and also cast to take a round rubber ring to
complete the seal when the water main has been drilled.

WS.18.6 Standard Main Ferrule Cock

Standard main ferrule cock shall be screw down and jumper

valve pattern 3/4 inch made of brass complying with B.S.
2579.

WS.18.7 Installation

Installation of the service connection shall only proceed

after the main pipe has been laid, tested and approved
and the trench has been inspected and approved by the
Engineer or his Representative.

The tapping saddle is first bolted around the main pipe

ensuring that the rubber ring completely surrounds and
does not obstruct the drilled hole. Care shall be
exercised during tapping to avoid damage to the main pipe
and the Contractor shall make good at his own cost any
main pipe which is damaged during tapping.

Tapping point shall not be within 6 inches from the main

pipe joint.

The ferrule cock is then screwed directly into the

tapping saddle. Ferrule cock must be turned on before the
works is covered.

The communication pipe shall be connected to the ferrule

cock by means of coupling bends and reducers where
necessary, and jointed with approved caulking material.
No bend or curve in any communication pipe shall be made
so as to diminish the waterway or alter the internal
diameter of the pipe in any part and no pipe shall be
laid so as to pass into or through precast concrete drain
block or manhole etc. The communication pipe shall be
cut to approved length to avoid such obstructions. The
communication pipe shall terminate with an approved
stop-end at point indicated on the Drawing or determined
by the Engineer or his Representative.

The Contractor shall satisfy the Engineer that the

service connection is leak-proof and should any leakage

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be detected he shall make good at his own expense to the
satisfaction of the Engineer.

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WS.18.8 Licenced Plumber

The works for the service connection shall be carried out

by a licenced plumber registered with the SYABAS or
Jabatan Bekalan Air and he shall be deemed to be familiar
with the normal practices and regulations of the relevant
Authority, and shall take all necessary steps to ensure
that the materials and workmanship comply with those
practices and regulations. The cost of ensuring such
compliance shall be deemed to be included in the Contract
Price.

WS.18.9 Inspection and approval by authority

The completed service connections shall be subject to the

approval of SYABAS or Jabatan Bekalan Air. The Contractor
shall give due notice as required by the relevant
Authority for the inspection and approval of the works
and shall be deemed to be allowed in his rate for such
inspection and approval, any fees payable, any temporary
suspension of the works and other costs resulting
thereby.

Should any works be covered without prior inspection and

approval, the Contractor shall uncover any part or parts
of the works or make openings in or through the same, as
the Authority may direct, for inspection. The Contractor
shall, at his own expense reinstate and make good such
part or parts to the satisfaction of the Authority and
Engineer.

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