Professional Documents
Culture Documents
WSA 1132002
PREFACE
This Standard was prepared by Power and Water Authority of the Northern Territory with the
assistance of the Water Corporation of Western Australia for the Water Services Association of
Australia (WSAA). WSAA also acknowledges the significant technical input of CSR Humes.
The objective of this Standard is to provide design, manufacturing and performance
requirements for manufacturers of thermoplastic lined reinforced concrete pipes. Given that a
standard for this product is not available from other overseas standards organisations, it is likely
that further improvements to this initial standard may be necessary as experience is gained with
its use.
Attention is drawn to the proposed publication of WSAA Rulings to this Standard. Where rulings
of public significance are issued, they will be available from the WSAA website
http://www.wsaa.asn.au/. When rulings are included in an amendment, the specific ruling will be
withdrawn at the time of publication of the amendment. Inquiries should be directed to WSAA
Sydney Office.
WSAA also invites comments and suggestions for amendments to this Standard. Please email
to david.cox@standards.com.au.
WSAA proposes to submit this Standard to Standards Australia International for development
into an Australian Standard.
Statements expressed in mandatory terms in notes to tables and figures are deemed to be
requirements of this Standard.
The terms normative and informative have been used in this Standard to define the
application of the appendix to which they apply. A normative appendix is an integral part of a
Standard, whereas an informative appendix is only for information and guidance.
This Standard will be withdrawn upon publication of an Australian Standard for thermoplastic
lined reinforced concrete pipe.
Comments should be forwarded to:
National Codes Manager
Water Services Association of Australia
GPO Box 5420, Sydney, NSW, 2001, Australia
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CONTENTS
page
PREFACE ...................................................................................................................................1
SECTION 1 SCOPE AND GENERAL .......................................................................................5
1.1 SCOPE..................................................................................................................................5
1.2 REFERENCED DOCUMENTS ..............................................................................................5
1.3 DEFINITIONS........................................................................................................................6
1.3.1 Lining arc ......................................................................................................................6
1.3.2 Lining blanket ................................................................................................................6
1.3.3 Lining continuity ............................................................................................................6
1.3.4 Lining defect..................................................................................................................6
1.3.5 Lining keys ....................................................................................................................6
1.3.6 Lining sheet...................................................................................................................6
SECTION 2 MATERIALS AND COMPONENTS ......................................................................7
2.1 GENERAL .............................................................................................................................7
2.2 REINFORCED CONCRETE PIPE MATERIALS ....................................................................7
2.3 LINING MATERIAL................................................................................................................7
2.3.1 PVC...............................................................................................................................7
2.3.2 PE .................................................................................................................................7
2.4 LINING COMPONENTS ........................................................................................................7
2.5 LINING COLOUR ..................................................................................................................7
2.6 LINING SHEET PHYSICAL PROPERTIES ...........................................................................8
2.7 LINING SHEET CHEMICAL RESISTANCE PROPERTIES ...................................................8
2.7.1 General .........................................................................................................................8
2.7.2 Specimens for change in mass tests .............................................................................8
2.7.3 Short Term Chemical Resistance..................................................................................8
2.7.4 Long Term Chemical Resistance ..................................................................................9
2.8 LINING COMPONENTS DEFECTS.......................................................................................9
SECTION 3 DESIGN AND MANUFACTURE .........................................................................11
3.1 REINFORCED CONCRETE PIPE .......................................................................................11
3.2 LINING SHEET AND COMPONENTS.................................................................................11
3.2.1 LINING SHEET KEYS .................................................................................................11
3.2.2 LINING COMPONENTS DIMENSIONS ......................................................................11
3.2.2.1 Lining Sheets .....................................................................................................11
3.2.2.2 Welding Strips....................................................................................................12
3.2.2.3 Joint Strips .........................................................................................................12
3.2.2.4 Lining Blankets...................................................................................................12
3.2.3 LINING SHEET WEIGHT ............................................................................................12
3.2.4 PIPE LINING FABRICATION ......................................................................................12
3.2.5 LINING ARC................................................................................................................12
3.3 LINING OF PIPE .................................................................................................................13
3.3.1 LINING OF HORIZONTALLY CAST PIPE...................................................................13
3.3.2 LINING OF VERTICALLY CAST PIPE ........................................................................13
3.4 WELDER QUALIFICATIONS ..............................................................................................14
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S E C T I O N
S C O P E
A N D
G E N E R A L
1.1 SCOPE
This standard applies to the manufacture of reinforced concrete pipes with flexible thermoplastic
lining sheet for the purpose of protecting the concrete from corrosion in aggressive sewage
environments. This standard applies to pipe sizes DN 600 and larger and to linings having flaps
to overlap joints and thus provide continuous corrosion protection.
1741
2758
2758.1
Concrete aggregates
3735
Supp 1
3894
3894.1
4058
ISO
37
62
175
176
178
527-1
868
1043-1
1043-2
1043-3
Plastics SymbolsPlasticizers
2039-1
2039-2
4599
4661-1
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1: Physical Tests
ASTM
A276
Standard specification for stainless and heat-resisting steel bars and shapes
D412
Standard Test Method for Vulcanized Rubber and Thermoplastic Rubbers and
Thermoplastic Elastomers - Tension (References ISO 37)
D543
D570
Standard Test Method for Water Absorption of Plastics (Equivalent to ISO 62)
D1004
Standard Test Method for Initial Tear Resistance of Plastic Film and Sheeting
(No similar/equivalent ISO standard)
D1203
Standard Test Method for Volatile Loss from Plastics Using Activated Carbon
Methods (Similar but not technically equivalent to ISO 176)
D2240
BS
5911100
Precast concrete pipes, fittings and ancillary productsPart 100: Specification for
Unreinforced and reinforced pipes and fittings with flexible joints
1.3 DEFINITIONS
For the purpose of this standard, the definitions below apply:
1.3.1 Lining arc
The circumference of the pipe over which a thermoplastic lining blanket is applied. The lining
arc includes at least the surface above the minimum sewage or effluent flow level at any time in
the life of the pipeline.
1.3.2 Lining blanket
The one piece lining for the pipe fabricated by cutting and welding of standard size and part
size thermoplastic sheets.
1.3.3 Lining continuity
The quality of a lining that determines its freedom from those defects which increase its
electrical conductivity.
1.3.4 Lining defect
A detectable weakness or discontinuity in the lining, which causes its ability to protect the
substrate from corrosion to be suspect during the normal service life.
1.3.5 Lining keys
Extensions or profiles on one face of the lining sheet for the purpose of securing the lining to
the concrete pipe.
1.3.6 Lining sheet
Lining of sizes as manufactured by extrusion and from which pipe lining blankets are cut or
fabricated and miscellaneous pipe lining accessory components are cut.
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S E C T I O N
M A T E R I A L S
A N D
C O M P O N E N T S
2.1 GENERAL
Thermoplastic sheet for lining of reinforced concrete pipe shall provide an impervious barrier to
liquids and gases and be inert to the sewage environment in which it is used.
Concrete constituents shall be chosen with consideration to the aggressiveness of the external
environment and where not fully lined, the aggressiveness of any sewage having industrial
discharge.
Where ASTM test methods are specified, the equivalent ISO test method may be used with the
written agreement of the Purchaser. Equivalent ISO test methods shall be as nominated in
Clause 1.3.
NOTE: Sulphate resisting (Type SR) cement provides resistance to neutral sulphates in soils and ground water.
Coarse and fine calcareous aggregates combined with increased cover to reinforcement reduce the rate of concrete
attack in acidic ground and sewage conditions. Refer to AS 3735 Supplement 1 for further guidance on materials
selection for reinforced concrete durability in aggressive environments.
The PVC compound used for lining components shall comprise of high molecular weight
polyvinyl chloride combined with plasticisers, stabilisers and pigments so as to be permanently
flexible. Polyvinyl chloride shall constitute not less than 99% by mass of the resin used. The
PVC compound shall not contain copolymer resins or fillers such as calcium carbonate.
2.3.2 PE
The polyethylene compound used for lining components shall comprise of linear low density
polyethylene (LLDPE) unless otherwise specified.
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NOTE:Note: Visibility for pipeline inspection is improved where a light coloured lining is used. However, non-black
lining may suffer ultraviolet degradation with prolonged exposure to sunlight and suitable lining and pipe storage
requirements may be required.
TEST METHOD
ACCEPTABLE LIMITS
Hardness
1.0% maximum
ASTM D570
0.10% maximum
ASTM D570
0.05% maximum
ASTM D1004
225% minimum
54 minimum 62 maximum
80 N/mm minimum
NOTE:
1
Specimens for tensile testing shall be prepared and tested using Die B.
Thermoplastic sheet for lining concrete pipes shall be resistant to sulphuric acid generated by
the hydrogen sulphide corrosion cycle of sewage and shall neither contribute to supporting the
growth of sewage bacteria and fungi, nor be affected by the enzymes or other end products of
such bacteria or fungi.
2.7.2 Specimens for change in mass tests
Specimens for determining change in mass shall be 75 mm x 25 mm and shall all have locking
profiles in identical positions.
2.7.3 Short Term Chemical Resistance
Lining test specimens shall be tested to ASTM D543 for change in mass, following exposure to
the chemical concentrations given in Table 2.2.
The change in mass shall not exceed the values given in Table 2.2 after 7 days exposure at
20C.
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Table 2.2
SHORT-TERM TEST EXPOSURE SOLUTIONS, CONCENTRATIONS AND ALLOWABLE
MASS CHANGE
CHEMICAL SOLUTION
CHEMICAL CONCENTRATION
0.20
Ferric chloride
0.60
Sodium chloride
0.15
Sulphuric acid
20
0.12
Nitric acid
0.20
Sodium hydroxide
0.20
Ammonium hydroxide
0.40
0.40
Sodium hypochlorite
Following initial conditioning to constant mass at 43C and exposure to the chemical solutions
given in Table 2.3 for 112 days at 25C 3, lining test specimens shall be tested in accordance
with:
(a)
(b)
The change in mass shall not exceed 1.5% for PVC and 0.5% for PE and the change in the
change in tensile strength at yield shall not exceed 15% for PVC and 12% for PE.
Table 2.3
LONG TERM TEST EXPOSURE SOLUTIONS AND CONCENTRATIONS
CHEMICAL SOLUTION 1
CHEMICAL CONCENTRATION
%
Sulphuric acid
20
Sodium hydroxide
Ammonia hydroxide
Nitric acid
Ferric chloride
Soap
0.1
0.1
NOTES:
1
All chemical solutions shall have a BOD of not less than 700 ppm.
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The lining manufacturer shall inspect all lining components for defects and shall spark test for
discontinuities all in accordance with the manufacturers printed procedures. All lining sheet
defects shall be repaired in accordance with the lining manufacturers printed procedures.
Lining sheet shall be retested and repaired until no defects are present.
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S E C T I O N
D E S I G N
A N D
M A N U F A C T U R E
(b)
(c)
(d)
(e)
When tested in accordance with Clause 20.6 and Appendix H of BS 5911-100, each size
and type of flexible joint shall sustain without loss of watertightness at the joint the
specified internal pressure under the conditions of deflection, straight draw and shear
specified in Clauses 20.6.1, 20.6.2 and 20.6.3 of BS 5911-100, respectively.
Pipes shall be either steam cured or water cured. For steam curing, commence a maximum of
one hour after completion of plastic lining. Maintain a uniform rate of increase and decrease in
pipe temperature until at least 50% of the characteristic compressive strength has been
achieved. For water curing, cure continuously for at least seven days and until at least 50% of
the characteristic compressive strength has been achieved.
NOTE: Load testing may be undertaken on unlined pipe, of the same materials, design and manufacturing method as
plastic lined pipe. External sacrificial layers shall be omitted for load testing.
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The top of the key used for lining horizontally cast pipe shall have a shape that will minimise
resistance to insertion into the concrete substrate while providing sufficient pull out resistance.
NOTE:
1
2
Flat welding strip used for repairs and sealing of miscellaneous field joints shall be of 25 mm
nominal width on the bottom face and 3 mm nominal thickness. Edges shall be bevelled.
3.2.2.3 Joint Strips
Where required, flat joint strips shall be 100 mm nominal width within tolerance of - 0 + 7 mm.
3.2.2.4 Lining Blankets
Lining blankets shall be cut and fabricated to size based on the pipe arc and the pipe length to
be lined and length of pipe joint flap for covering the pipe joints.
3.2.3 LINING SHEET WEIGHT
2
PVC lining sheet shall have a minimum mass of 2.5 kg/m . PE lining sheet shall have a
2
minimum mass of 2.9 kg/m .
3.2.4 PIPE LINING FABRICATION
Pipe lining blankets shall be fabricated from standard sheets and/or part sheets by lapping
sheets a minimum of 12 mm and applying adequate heat and pressure to the lap, using
automatic hot air or high frequency shop welding processes, to produce a continuous welded
joint. Sheets for fabricating the lining blanket shall be of dimensions that will minimise the total
welding length.
All welding shall be in accordance with the lining manufacturers written instructions for sheet
jointing work.
Welded joints shall be free from cracks, separations or incompletely fused weld edges which
are visible or which permit entry to an 0.1 mm feeler gauge by more than 3 mm of feeler gauge
length.
Transverse flaps provided at the end of pipe lining blankets for pipe joint overlap shall have
backing keys removed such that not more than 1 mm height of key remains.
For vertically cast pipe, keying shall be removed up to 40 mm from the end of the inside surface
of the pipe section. For horizontally cast pipe, sufficient keying shall be removed to ensure that
the keying adjacent to the ends of the pipe barrel will not be closer than 13 mm from the barrel
end.
Transverse flaps provided at the spigot end of pipes shall extend at least 100 mm beyond the
end of the spigot end face.
Lining blankets for horizontally cast pipes shall be produced so that continuous ribs for keying
are circumferentially disposed. Lining for vertically cast pipe shall be produced so that
continuous ribs for keying are longitudinally disposed.
3.2.5 LINING ARC
The circumferential arc of pipes to be lined shall be designed to achieve 359 coverage. The
tolerance on the actual lining arc achieved shall be +0.5 4.0.
NOTE: The accuracy in achieving a specified lining arc is affected by the tolerance on cutting the lining, the tolerance
allowed for the internal diameter and any change in lining length due to temperature change. The last two factors are
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WSA 1132002
more significant for horizontally cast pipe. Ensuring a specified lining arc is achieved, requires providing a lining to
cover that arc for at least the maximum internal diameter that is possible after applying the tolerances allow for in the
casting method (and also making allowances for any dimension changes due to temperature variations).
Lining of horizontally cast pipe with the lining blanket shall be undertaken immediately following
manufacture of the pipe while the concrete is still green and compliant to allow lining keys to be
embedded.
The lining shall be heated to an appropriate temperature so that it may be sufficiently pliant for
application while still retaining sufficient rigidity of keys for insertion into the concrete.
Where the lining has continuous ribs for keying, the ribs shall be aligned circumferentially in the
pipe so as to allow moisture or fluid accumulating between the lining and the pipe to escape
towards the unlined part of the pipe.
Where the lining has continuous ribs, the lining shall be positioned to ensure:
(a)
the lining ribs at each lining end are not closer than 13 mm from the barrel end; and
(b)
the distance between ribs on either side of a pipe joint will not be greater than 130 mm.
The lining shall be positioned to ensure that any joint flap extends at least 100 mm beyond the
end of the inside surface of the spigot.
Where pipes have elliptical steel reinforcing to achieve higher pipe strength on one axis, the
gap in the lining sheet shall be equidistant about the nominated pipe invert or the invert of the
lined pipe shall be within 10 of true pipe invert.
The lining shall be held in longitudinal tension by suitable means while lining keys are
embedded into the concrete substrate so as to ensure there is no wrinkling or bulging of the
lining. The keys shall be embedded to ensure the lining is hard against the underlying concrete
and that circumferential corrugations on the surface of the liner are within tolerances specified.
Care shall be taken when removing the lining embedment equipment to prevent damage to the
lining. Any holes made in the lining for manufacturing purposes shall be clearly marked for weld
sealing.
3.3.2 LINING OF VERTICALLY CAST PIPE
Lining for vertically cast pipe shall be placed on the face of the inner mould prior to placement
of concrete between the inner and outer moulds.
For 359 lining arcs or less, plastic strips or similar shall be used to hold the ends of the lining
arc firmly against the inner mould in order to prevent mortar entering between the lining and the
inner mould. The strips shall be secured by screws or similar through the inner mould.
Where the lining is installed as a tube but is not to be a 360 lining, keying shall be removed
from the section of lining in the invert that will be later cut away.
Where the lining has continuous ribs for keys, the sheet shall be aligned with the ribs
longitudinal to the pipe so as to allow moisture or fluid accumulating between the lining and pipe
to escape and to facilitate casting.
The lining shall be positioned to ensure:
(a)
the lining keys terminate not more than 40 mm from the end of the inside surface of the
pipe section; and
(b)
any joint flap extends at least 100 mm beyond the end of the inside surface of the spigot.
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Where pipes have elliptical steel reinforcing to achieve higher pipe strength on one axis, the
gap in the lining sheet shall be equidistant about the nominated pipe invert due to reinforcement
disposition.
The lining blanket shall be held in tension by plastic or metal bands at the top and bottom of the
mould or similar so as to ensure there is no wrinkling or bulging of the lining.
Care shall be taken when removing the inner mould to prevent damage to the lining. Screws,
nails or other securing ties through the lining shall be removed with care and without tearing the
lining prior to removal of the moulds. Sharp instruments shall not be used to pry the mould from
the lining. Any holes made in the lining for manufacturing purposes shall be clearly marked for
weld sealing.
All nail and tie holes in the lining blanket made for manufacturing the plastic lined concrete pipe
shall be patched in accordance Appendix E and the manufacturers written procedures.
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S E C T I O N
P E R F O R M A N C E
R E Q U I R E M E N T S
4.1 GENERAL
Where ASTM test methods are specified, the equivalent ISO test method may be used with the
written agreement of the Purchaser. Equivalent ISO test methods shall be as nominated in
Clause 1.3.
(b)
Diameter by more than 5 mm for pipe DN 1800 10 mm for pipe >DN 1800.
NOTE: Such tolerances are additional to the dimensional tolerances permitted for unlined concrete pipe to AS 4058.
The unlined section width shall be within the tolerances specified by the purchaser.
Pipe with mortar over the edge of the blanket shall be rejected or otherwise repaired where
agreed by the purchaser or the purchasers representative.
The lining ends shall be square with the pipe ends.
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Pipes shall be rejected where concrete defects cause projections or depressions of the lining
greater than one half the cover unless otherwise agreed by the purchaser or the purchasers
representative to be repaired.
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S E C T I O N
S E C T I O N 5
M A R K I N G
P A C K A G I N G
A N D
5.3 PACKAGING
Prior to receipt by the purchaser, suitable packaging or protection shall be given to the pipe
lining to prevent:
(a)
(b)
Exposure of the lining to ultraviolet radiation where the lining is not black.
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APPENDIX A
PURCHASING GUIDELINES
(Informative)
A1 SCOPE
This Appendix includes the technical provisions necessary for the supply of plastic lined
reinforced concrete pipe, but does not contain all the necessary provisions of a contract. In a
number of clauses, the purchaser is either asked to state the requirements or is given a choice
of optional requirements, and these are contractual matters to be agreed between the purchaser
and the manufacturer.
This Appendix also contains detailed explanation, advice and recommendations on the
information to be supplied by the purchaser at the time of the enquiry or order. Its aims are to
prevent misunderstanding and to result in satisfactory supply of products and services.
A2 INFORMATION TO BE SUPPLIED BY THE PURCHASER
The following information should be supplied by the purchaser:
(a)
(b)
(c)
The colour of the lining. The default colour is black if not otherwise specified.
(d)
The number of pipes to be lined and the respective nominal sizes, load classes, effective
pipe lengths and joint type.
(e)
The type of cement and aggregates to be used for pipe manufacture, cover to
reinforcement and any requirements for admixtures.
(b)
(c)
(d)
The size of sheets from which the pipe lining is fabricated in mm.
(e)
(f)
(g)
(h)
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APPENDIX B
MEANS FOR 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)
(b)
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. Product certification schemes
provide independent assurance of the claim by the manufacturer that products comply with
standards and are thereby fit for their intended use in pipeline and plumbing systems
B3 PRODUCT CERTIFICATION
The certification scheme shall meet the criteria described in SAA HB18.28/SANZ HB18.28
(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 accreditation
body that is acceptable to JAS-ANZ.
The frequency of the sampling and testing plan as detailed in Paragraph B4.1 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.
B4 TESTING
B4.1 GENERAL
Table B4.1 sets out the minimum sampling and testing frequency plan for a manufacturer to
demonstrate compliance of product(s) to this Standard.
B4.2 RETESTING
In the event of a test failure, the products manufactured since the previous test(s) conforming to
the requirements outlined in Table B4.1 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.
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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.
B4.3 REJECTION AFTER RETEST
In the event of a quarantined batch being rejected after retesting in accordance with the
procedures set out in Paragraph B4.2, 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.
TABLE B4.1
MINIMUM SAMPLING FREQUENCY FOR TESTING AND INSPECTION
CHARACTERISTIC
CLAUSE
REQUIREMENT
TEST METHOD
FREQUENCY
Type Tests
Materials
PVC or PE composition
(Conformance or test
certificates)
Hardness
Shore Durometer
Tensile strength
ASTM D412
Elongation at break
ASTM D412
Plasticiser permanence
Water absorption
ASTM D570
ASTM D570
Tear strength
ASTM D1004
Chemical resistance
Lining components
defects
3.4.1
3.4.1
3.4.2
Welding strip
At any change in
material
formulation or
design
3.4.3
Joint strip
Joint lap tensile strength
ASTM D412
At any change in
material
formulation or
design
2.3
2.5
2.6.4
2.7
Dimensions
Lining fabrication
Performance Tests
CHARACTERISTIC
4.5
Overlap dimension
Measuring tape
3.6
4.1
Appendix C
4.2
4.3
Measuring devices
4.4
Lining finish
Measuring devices
CLAUSE
REQUIREMENT
TEST METHOD
Every 5 years or
at any change in
material
formulation
Every 5 years or
at any change in
material
formulation or
design
Every 5 years or
change in material
formulation or
lining design
FREQUENCY
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Base sheet for lining
2.7
Dimensions
Lining components
defects
Each sheet
1 in 20 sheets
3.4.1
Lining sheet keys
3.4.2
Welding strip
3.4.3
Joint strip
Lining fabrication
3.6
Overlap dimension
1 in 20 strips
Measuring tape
Each sheet
ASTM D412
1 in 20 sheets
Four successive
pipes from initial
production batch
4.2
Appendix D
Each pipe
4.3
Measuring devices
4.4
Lining finish
Measuring devices
Appendix C
1 from first 40
pipes of each pipe
size and load
class
ASTM D412
1 in 100 lining
blankets
Chemical resistance
1 in 500 lining
sheets
4.5
Performance Tests
4.1
4.1
4.5
2.6.3
B5 DEFINITIONS
B5.1 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 knowingly to supply any nonconforming unit of product.
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B5.5 LOT
A clearly identifiable sub-division of a batch for inspection purposes.
B5.6 SAMPLE
One or more units of product drawn from a batch or lot, selected at random without regard to
quality.
NOTE: The number of units of product in the sample is the sample size.
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APPENDIX C
LINING KEY PULL-OUT RESISTANCE
(Normative)
C1 SCOPE
This Appendix sets out a method for determining the resistance of the lining to being detached
from the underlying concrete substrate following curing of the concrete pipe.
C2 PRINCIPLE
A pull off load is applied to the thermoplastic pipe lining for a specified period to determine
whether the lining will be retained fastened to the concrete pipe wall by the keys on the back of
the lining.
C3 APPARATUS
The following apparatus is required:
(a)
An appropriate clamp to attach to the lining for the purpose of applying a load
(b)
Loading apparatus capable of applying a force of 17.5 N per lineal mm length of key
(c)
A suitable marker, such as chalk or a spirit pen and of contrasting colour to the lining, e.g.
white where lining is black, for marking the location of defects on the lining.
C4 PROCEDURE
(a)
(b)
Test under ambient temperature of 20 to 27C at least 14 days after lining of pipe.
(c)
At the mid length of the pipe diametrically opposite the invert, mark a lining test area to be
cut being 40 to 50 mm either side of a ribbing key or a line of individual keys and 100 to
200 mm long.
(d)
Make two knife cuts parallel to and 40 to 50 mm either side of a rib type key or a line of
individual keys and 100 to 200 mm long. Where the key is a rib, use an abrasive wheel
cutter to make two transverse cuts at the ends of the knife cuts deep enough to severe
the ribs. Otherwise, where the keys are individual use a knife for the transverse cut.
(e)
Examine the surface of the concrete under the cut lining and record the type and number
of defects.
(f)
(g)
Apply a force of 17.5 N per lineal mm of key length to the clamp, perpendicularly to the
liner and maintain for 1 minute.
(h)
Remove the load and clamp and examine the lining test area keying.
(i)
At 0.6 to 0.9 m from the mid-length towards the spigot and diametrically opposite the
invert repeat the preparation and testing described in c) to h) above.
(j)
At 0.6 to 0.9 m from the mid-length towards the socket and diametrically opposite the
invert repeat the preparation and testing described in c) to h) above.
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(k)
Where in any of the test locations, the lining pulls away from the underlying concrete and
indicates movement or breakage of the retaining key or spalling of the concrete, the test
will have been failed.
(l)
Progressively extend pull-out testing away from the failed key area so as to determine the
extent of on conforming key embedment.
(m)
Repair of the test pipe shall be permitted where the non-conforming key embedment area
2
is less than 0.05 m in any single pullout location.
(n)
Repair concrete defects or reject pipe in accordance with the defects acceptability and
repair requirements in AS 4058.
C5 TEST REPORT
The test report shall include the following:
(a)
(b)
Date of test.
(c)
(d)
The nature of the failure, e.g. movement of the key, breakage of the key, spalling of the
concrete.
(e)
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WSA 1132002
APPENDIX D
LINING CONTINUITY
(Normative)
D1 SCOPE
This Appendix sets out a method for determining the presence of defects in the lining, such as
pin holes, tears and weld failures, which would prevent the lining from providing a barrier to
concrete corrosion.
D2 PRINCIPLE
A pipe lining is firstly visually inspected for defects and then subsequently tested, using a
calibrated spark testing instrument, for discontinuities that may cause the lining to be ineffective
in preventing corrosion of the underlying concrete.
D3 APPARATUS
The following apparatus is required:
(a)
Spark testing equipment calibrated to 20 000 V and according with the requirements of
Clause 7 of AS 3894.1.
(b)
An approved weld probing device such as a 0.15 mm feeler gauge or a blunt screwdriver.
(c)
A suitable marker, such as chalk or a spirit pen and of contrasting colour to the lining, e.g.
white where lining is black, for marking the location of defects on the lining.
D4 PROCEDURE
(a)
Inspect the lining carefully for visible defects, such as cuts, tears, or cracks and open or
incompletely fused welds.
(b)
Probe all welds with the probing device to determine all defective welds requiring
rewelding, i.e. weak welds and welds where the probe enters more than 3mm.
(c)
Identify all defects with the marker and determine whether there any major defects. Minor
defects are defined in Appendix E.
(d)
Where there are major defects reject the lining or lined pipe unless otherwise agreed by
the purchaser or the purchaser representative that the defects may be repaired.
(e)
Where all detected defects are minor, repair defects using qualified welders in
accordance with Appendix E and the manufacturers printed procedures.
(f)
If any charring of welds occurs during repair due to overheating, replace all charred
sections in accordance with Appendix E and the manufacturers printed procedures.
(g)
Ensure that the spark testing equipment has been calibrated within the last 12 months in
accordance with Appendix C of AS 3894.1.
(h)
Allow 20 minutes for the spark testing instrument to reach equilibrium conditions with the
environment. The 20 minutes is to include 10 minutes for warming up the instrument after
it is switched on.
(i)
(j)
Adjust the voltage of the spark testing equipment to 15000 +1000 0 volts.
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(k)
(l)
Pass the brush electrode over the pipe lining at a rate of not greater than 0.3 m/s
maintaining contact between the electrode and the test area, using an appropriate motion.
(m)
Where the instrument indicates a discontinuity determine the exact location of the
discontinuity (do not hold electrode stationary against the surface) and clearly identify it
on the test surface with the marker.
(n)
Continue testing until the whole of the lining has been assessed.
(o)
Count and record the number of discontinuities found, expressing them as defects per
square metre of total lining area.
(p)
Where there is more than one discontinuity per square metre, undertake repair only with
the approval of the purchaser or purchasers representative.
(q)
(r)
Repeat spark testing and repair {steps g) to m) and p)} until there are no discontinuities
detected.
D5 TEST REPORT
The test report shall include the following:
(a)
(b)
Date of test.
(c)
(d)
(e)
For each pipe tested, the number of lining defects and the nature of each defect.
(f)
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APPENDIX E
LINING DEFECTS AND REPAIR
(Normative)
E1 DEFECTS CLASSIFICATION
Defects in lining blankets are described as major and minor where minor defects are:
2
(a)
(b)
Damage such as cuts and tears over an area not greater than 0.04 m .
(c)
Short incomplete welds, i.e. incomplete or unfused welds individually not more than
25 mm in length or not more than 250 mm in any one metre length.
(d)
(e)
Lining projections and depressions between one quarter and one half the concrete cover.
(f)
Unembedded keys over an area not exceeding 0.04 m of a plastics lining area.
(g)
(h)
E2 DEFECTS TO BE REPAIRED
Minor defects a), b), c), d), e) and h) shall be repaired in accordance with this Appendix and the
manufacturers printed procedures.
Minor defects f) and g) do not require repair.
Repair of major defects shall only be undertaken, where agreed by the purchaser or purchasers
representative. Repair of major defects shall be in accordance with this Appendix and the
manufacturers printed procedures.
E3 WELDING STRIPS FOR REPAIR
Where welding strips are used in repair, test tabs shall be left at the ends of the welding strip in
order to perform a pull test.
E4 REPAIR METHODS
E4.1 Pinholes, Cuts and Tears
Isolated pinholes, and straight cuts and tears whose cut or torn edges can be brought together
shall be repaired by welding flat welding strip centrally over the defect.
E4.2 Damaged Sections
Damaged sections, which cannot be repaired using a welding strip, shall be replaced.
Replacement shall be as follows:
(a)
(b)
(c)
Tack weld the patch in place with no gap greater than 4 mm.
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(f)
Cut a lining patch at least 12 mm larger all round than the shape removed.
(g)
(b)
(c)
Cut the lining no more than necessary to effect concrete repair or key re-embedment.
(b)
(c)
(d)
Reposition the cut lining and re-embed the lining keys while expelling any entrapped air.
(e)
Hold the lining in place with steel strips strutted diagonally for at least 24 h.
(f)
Punch a hole in test tabs provided at each end of the welding strip (welding strips to be
extended 50 mm beyond welding length each end to provide test tabs).
(b)
(c)
If weld failure occurs on application of force, maintain the 50 N pulling force until weld
separation ceases.
(d)
(e)
Repeat pull test and repair until pull test does not open the weld.
(f)
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APPENDIX F
HANDLING, STORAGE AND TRANSPORT
(Informative)
Handling, storage and transport of plastics lined reinforced concrete pipes shall be in
accordance with the product manufacturer's printed requirements.
Notwithstanding the manufacturers requirements, the following requirements shall be met:
(a)
Use only lifting and transportation equipment which does not contact plastics lining or
plastics accessories except when approval has been received from the purchasers
representative allowing use of equipment having padding or protective systems to prevent
damage.
(b)
Protect plastic lining accessories, such as welding strip during handling, storage and
transport until secured in the completed installation.
(c)
Secure lining flaps protruding from pipe ends to prevent severe changes in the direction
of the flap.
(d)
(e)
Provide secure, clean and dry storage areas for plastics lining work materials and tools.
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