33 05 05.31 - Hydrostatic Testing.pdf
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- Attached to
- Contract 2026-01: Maintenance & Emergency Contract (Excavation) – Project No. 7297. 0444
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- York County, Pennsylvania
About this file
This is a technical specification document for hydrostatic testing procedures prepared by Herbert, Rowland & Grubic, Inc. for West Manchester Township's Contract 2026-01: Maintenance & Emergency Contract (Excavation) in Pennsylvania. The specification establishes requirements for hydrostatic testing of pressure piping systems, including ductile iron, PVC, and polyethylene (PE) piping commonly used in municipal sanitary sewer force mains and low-pressure sanitary sewer collection systems. Before commencing testing activities, contractors must submit testing procedures, a list of test equipment, testing sequence schedules, provisions for flushing and test water disposal, and test gage calibration certificates. The specification requires contractors to perform hydrostatic testing to verify the acceptance of installed pressure piping and to identify, correct, and retest any failures until successful results are achieved.
Testing procedures are established according to AWWA C600 standards for ductile iron and PVC piping and ASTM F2164 standards for PE piping. Standard test pressure is 150 psi unless the Township Engineer requires higher pressure based on material specifications. For ductile iron and PVC piping, testing must be conducted for at least two hours with pressure maintained within plus or minus 5.0 psi of test pressure, with maximum allowable leakage calculated using a specified formula based on pipe length, diameter, and average test pressure. For PE piping, testing includes a four-hour initial expansion phase followed by a one-hour pressure monitoring phase at a reduced pressure of 10 psi below the target pressure. All visible leakage must be corrected regardless of quantity, and any piping showing leakage greater than allowable limits must be located, repaired, and retested until acceptance criteria are met.
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Text version
33 05 05.31 - HYDROSTATIC TESTING
Herbert, Rowland & Grubic, Inc. 33 05 05.31 - 1 007297.0444
SECTION 33 05 05.31 - HYDROSTATIC TESTING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: Hydrostatic testing of pressure piping.
B. Related Requirements:
1. Section 33 31 23 - Sanitary Sewerage Force Main Piping: Pipe materials and accessories normally encountered with municipal sanitary sewage force mains.
2. Section 33 31 26 - Sanitary Pressure Sewer Piping: Pipe materials and accessories normally encountered with low-pressure sanitary sewage collection systems where on-lot grinder pumps convey domestic sewage.
1.2 REFERENCE STANDARDS
A. American Water Works Association:
1. AWWA C600 - Installation of Ductile-Iron Water Mains and Their Appurtenances.
B. American Standard Testing Methods:
1. ASTM F 2164 - Standard Practice for Field Leak Testing of Polyethylene (PE) and
Crosslinked Polyethylene (PEX) Pressure Piping Systems Using Hydrostatic Pressure.
1.3 SUBMITTALS
A. Section 01 33 00 - Submittal Procedures: Requirements for submittals.
B. Submit following items prior to start of testing:
1. Testing procedures.
2. List of test equipment.
3. Testing sequence schedule.
4. Provisions for disposal of flushing and test water.
5. Certification of test gage calibration.
C. Test and Evaluation Reports: Indicate results of piping tests.
1.4 REQUIREMENTS
A. Hydrostatic Testing shall be performed to determine the acceptance of the pressure piping installed.
B. The Contractor shall determine and correct the causes of test failure and retest until successful test results are achieved.
Herbert, Rowland & Grubic, Inc. 33 05 05.31 - 2 007297.0444
PART 2 - PRODUCTS
2.1 HYDROSTATIC TESTING
A. Equipment:
1. Pressure pump.
2. Pressure hose.
3. Water meter.
4. Test connections.
5. Pressure relief valve.
6. Pressure Gage: Calibrated to 0.1 psi.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Section 01 73 00 - Execution Requirements: Requirements for installation examination.
B. Verify that piping is ready for testing.
C. Verify that trenches are backfilled.
D. Verify that pressure piping thrust restraints have been installed.
3.2 FIELD QUALITY CONTROL
A. Section 01 40 00 - Quality Requirements: Requirements for inspecting and testing.
B. Testing of Pressure Ductile Iron or PVC Piping:
1. Test system according to AWWA C600 and following:
a. Hydrostatically test each portion of pressure piping, including valved section, at 150 psi unless Township and/or Township Engineer requires a higher testing pressure based on the material.
b. Conduct hydrostatic testing for at least two hours.
c. Slowly fill with water portion of piping to be tested, expelling air from piping at high points.
d. Install corporation cocks at high points.
e. Close air vents and corporation cocks after air is expelled.
f. Raise pressure to specified test pressure.
g. Observe joints, fittings, and valves undergoing testing.
h. Remove and renew cracked pipes, joints, fittings, and valves that show visible leakage.
i. Retest.
j. Correct visible deficiencies and continue testing at same test pressure for additional two hours to determine leakage rate.
k. Maintain pressure within plus or minus 5.0 psi of test pressure.
l. Leakage is defined as quantity of water supplied to piping necessary to maintain test pressure during period of testing.
m. Compute maximum allowable leakage using following formula:
Herbert, Rowland & Grubic, Inc. 33 05 05.31 - 3 007297.0444
1) L = [SD x sqrt(P)]/C.
2) L = testing allowance, gph.
3) S = length of pipe tested, feet.
4) D = nominal diameter of pipe, inches.
5) P = average test pressure during hydrostatic testing, psig.
6) C = 148,000.
7) If pipe undergoing testing contains sections of various diameters, calculate allowable leakage from sum of computed leakage for each pipe size.
2. If testing of piping indicates leakage greater than that allowed, locate source of leakage, make corrections, and retest until leakage is within acceptable limits.
3. Correct visible leaks regardless of quantity of leakage.
C. Testing of Pressure PE Piping:
1. Test system according to ASTM F2164 and following:
a. Hydrostatically test each portion of pressure piping, including valved section, at 150 psi unless Township and/or Township Engineer requires a higher testing pressure based on the material.
b. Initial expansion phase:
1) Slowly fill with water portion of piping to be tested, expelling air from piping at high points.
2) Install corporation cocks at high points.
3) Close air vents and corporation cocks after air is expelled.
4) Raise pressure to specified test pressure.
5) Observe joints, fittings, and valves undergoing testing.
6) Add make-up water as necessary to maintain maximum test pressure for 4 hours.
c. Test Phase:
1) Immediately after expansion phase, reduce test pressure by 10 psi and stop adding makeup water.
2) Monitor pressure for 1 hour.
d. Remove and renew cracked pipes, joints, fittings, and valves that show visible leakage.
e. Retest after section is depressurized for 8 hours, minimum.
f. If no visual leakage is observed and test pressure remains within 5% of the target pressure, no leakage is indicated.
2. If testing of piping indicates leakage, locate source of leakage, make corrections, and retest until leakage is within acceptable limits.
3. Correct visible leaks regardless of quantity of leakage.
END OF SECTION
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