41-02300 HDPE Pipe.pdf

SECTION 02300

HIGH DENSITY POLYETHYLENE PIPE DIVISION 2

West Branch Regional Authority 02300-1 January 2026 Route 54 Sanitary Sewer Extension Project High Density Polyethylene Pipe Contract No. WB-1

PART 1 - GENERAL

1.01 DESCRIPTION OF WORK

A. Scope

1. The Contractor shall provide all plant, labor and material required to furnish, install, test and place in operation the High Density Polyethylene (HDPE) piping systems required for the Project as set forth on the Drawings and in accordance with this section of the Specifications.

2. The provisions of this section shall apply to all HDPE pipe and piping systems specified in this Division are presented on the Drawings.

B. Related Work Specified Elsewhere in Contract Documents

1. Section 01600: Materials and Equipment

2. Section 02000: Site Work General Provisions

3. Section 02205: Earthwork for Pipelines

4. Appendix No. 1 - Standard Specifications for Extensions of and Connections to the West Branch Regional Authority Sanitary Sewer System, April 2014

5. Section 02310: Horizontal Directional Drilling HDPE Pipe

6. Section 15070: Piping System Appurtenances

1.02 REFERENCE STANDARDS

A. Reference Standards

1. AWWA C901: Standard for Polyethylene (PE) Pressure Pipe and Tubing, ½" (13mm) through 3" (76mm) for Water Service.

2. AWWA C906: Standard Specification for Polyethylene (PE) Pressure Pipe and

Fittings, 4" (100mm) through 63" (1575mm) for Water Distribution and Transmission.

3. ASTM D2657: Standard Practice for Heat Joining Polyolefin Pipe and Fittings.

4. ASTM D2683: Standard Specification for Socket-Type Polyethylene Fittings for

Outside Diameter-Controlled Polyethylene Pipe and Tubing.

5. ASTM D2837: Standard Test Method for Obtaining Hydrostatic Design Basis for

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Thermoplastic Pipe Materials or Pressure Design Basis for Thermoplastic Pipe Products.

6. ASTM D3261: Standard Specification for Butt Heat Fusion Polyethylene (PE)

Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing.

7. ASTM D3350: Standard Specification for Polyethylene Plastic Pipe and Fittings

Materials.

8. ASTM F1055: Standard Specification for Electro fusion Type Polyethylene Fittings for Outside Diameter Controlled Polyethylene Pipe and Tubing.

9. PPI TR-3: Policies and Procedures for Developing Hydrostatic Design Basis (HDB), Pressure Design Basis (PDB), Strength Design Basis (SDB) and Minimum Required Strength (MRS) Ratings for Thermoplastic Piping Materials and Pipe.

10. PPI TR-4: PPI Listing of Hydrostatic Design Basis (HDB), Strength Design Basis

(SDB), Pressure Design Basis (PDB) and Minimum Required Strength (MRS) Ratings for Thermoplastic Piping Materials or Pipe.

11. NSF/ANSI 61: Standard for Drinking Water Systems Components Health Effects.

12. CSA B137.1: Polyethylene Pipe, Tubing and Fittings for Cold-Water Pressure

Services.

13. PPI TR-33: Generic Butt Fusion Joining Procedure for Polyethylene Gas Pipe.

14. PPI TR-41: Generic Saddle Fusion Joining Procedure for Polyethylene Gas Piping.

15. AWWA M55: Manual for the Design and Installation of Polyethylene Pipe in Water

Applications.

16. PPI TR-14: Water Flow Characteristics of Thermoplastic Pipe.

17. PPI TR-34: Disinfection of Newly Constructed Polyethylene Water Mains.

1.03 QUALITY ASSURANCE

A. Refer to requirements in Section 01000: Summary of Work and Special Requirements.

B. Refer to requirements in Section 15136: Basic Piping Materials and Methods.

C. The HDPE pipe and fittings shall be manufactured in a plant capable of providing continuous quality control through inspection. The facility shall have the necessary testing equipment to verify that the pipe and fittings meet the requirements of AWWA C901 or

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C906, NSF Standard #61 and ASTM Standards.

D. The HDPE pipe and fittings manufacturer shall have an ongoing Quality Control program for incoming and outgoing materials. HDPE resins shall be checked for density, melt flow rate and contamination. The manufacturer of the resin shall certify the Cell Classification in accordance with the requirements of ASTM D3350.

E. Molded fittings shall be inspected for voids and knit lines. All fabricated fittings shall be inspected for joint quality and alignment. All fabricated fitting welds shall be made using a DataLogger. A record of the temperature pressure and graph of the fusion cycle shall be maintained by the fitting manufacturer.

F. The manufacturer of the pipe and fittings shall maintain permanent QC and QA records.

DataLogger records shall be maintained on fabricated fittings.

1.04 SUBMITTALS

A. Refer to requirements in Section 01340: Shop Drawings, Product Data and Samples.

1.05 WARRANTY AND GUARANTEE

A. The manufacturer shall provide a warranty against manufacturing defects of material and workmanship for a period of ten years (10) after final acceptance of the Project by the Owner. The manufacturer shall replace at no expense to the Owner any defective pipe/fitting material including labor within the warranty period.

1.06 STORAGE AND HANDLING

A. During loading, transportation and unloading, every precaution shall be taken to prevent injury to the pipe. No pipe shall be dropped from cars or trucks or allowed to roll down slides without proper retaining ropes. During transportation, each pipe shall rest on suitable pads, strips, skids or blocks securely wedged or tied in place. Any pipe damaged shall be replaced.

B. The manufacturer shall package the pipe in a manner designed to deliver the pipe to the

Project neatly, intact and without physical damage. The transportation carriers shall use appropriate methods and intermittent checks to ensure the pipe is properly supported, stacked and restrained during transportation such that the pipe is not nicked, gouged, or physically damaged.

C. Pipe shall be stored on clean, level ground to prevent undue scratching or gouging. If the pipe must be stacked for storage, such stacking shall be done in accordance with the pipe manufacturer’s recommendations. The pipe shall be handled in such a manner that it is not pulled over sharp objects or cut by chokers or lifting equipment.

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D. Sections of pipe having been discovered with cuts or gouges in excess of 10% of the pipe wall thickness shall be cut out and removed. The undamaged portions of the pipe shall be rejoined using the heat fusion joining method.

E. Fused segments of the pipe shall be handled so as to avoid damage to the pipe. Chains or cable type chokers must be avoided when lifting fused sections of pipe. Nylon slings are preferred. Spreader bars are recommended when lifting long fused sections.

1.07 MANUFACTURER

A. All HDPE pipe and fittings shall be from a single manufacturer, who is fully experienced, reputable and qualified in the manufacture of the HDPE pipe to be furnished. The pipe shall be designed, constructed and installed with the best practices and methods and shall comply with these Specifications.

PART 2 - PRODUCTS

2.01 GENERAL

A. All polyethylene pipe, tubing and fittings furnished under this specification shall conform to all applicable provisions and requirements of the latest revision of AWWA C901, C906 or CSA B137.1 and, by inclusion, all appropriate standards reference therein.

B. Polyethylene compounds utilized in the manufacture of products furnished under this specification shall be listed in PPI TR-4, have a minimum grade of PE345 for PE3408 materials, as defined in ASTM D3350. In conformance with AWWA C901, AWWA C906, or CSA B137.1, they shall have a PPI recommended Hydrostatic Design Basis (HDB) of 1600 psi (PE3408) at a temperature of 73.4 F (23 C).

C. All materials which come in contact with water, including lubricants, shall be evaluated, tested and certified for conformance with NSF/ANSI Standard 61.

D. Clean re-work material of the same grade and cell classification generated from the manufacturer’s own pipe and fitting production may be used by the same manufacturer as long as the pipe, tubing and fittings produced meet all the requirements of AWWA C901, AWWA C906, or CSA B137.1.

2.02 PIPE SIZES 3-INCH DIAMETER AND LARGER

A. Materials used for the manufacture of polyethylene pipe and fittings shall be made from a PE 3408/PE 4710 DIPS High Density Polyethylene resin compound meeting cell classification 445574C. Pipe shall be DIPS, DR11 (200 psi WPR).

B. Pipe O.D. sizes shall be available in ductile iron pipe sizes (DIPS). Pipe shall have a manufacturing standard of ASTM D3035 and be manufactured by an ISO 9001 certified

West Branch Regional Authority 02300-5 January 2026 manufacturer.

C. The pipe shall contain no recycled compounds except that generated in the manufacturer's own plant from resin of the same specification from the same raw material. The pipe shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions, voids, or other injurious defects.

D. All pipes shall be suitable for use as pressure conduits, listed as NSF 61 and as per

AWWA Class (PC) 100 have a nominal burst value of three and one-half times the Working Pressure Rating (WPR) of the pipe.

2.03 PIPE SIZES 2-INCH DIAMETER AND LESS

A. Materials used for the manufacture of polyethylene pipe and fittings shall be made from a PE 4710 CTS Dimension High Density Polyethylene resin compound meeting cell classification 445574E. Pipe shall have a manufacturing standard of ASTM D2737 (CTS).

Pipe shall be DR 9 (250 PSI WPR) unless otherwise specified on the plans.

B. Pipe O.D. sizes shall be available in copper tube size (CTS) and ductile iron pipe sizes

(DIPS). Pipe shall have a manufacturing standard of ASTM D3035 and be manufactured by an ISO 9001 certified manufacturer.

C. The pipe shall contain no recycled compounds except that generated in the manufacturer's own plant from resin of the same specification from the same raw material. The pipe shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions, voids, or other injurious defects.

D. All pipes shall be suitable for use as pressure conduits, listed as NSF 61 and as per

AWWA Class (PC) 100 have a nominal burst value of three times the Working Pressure Rating (WPR) of the pipe.

2.04 FITTINGS, COUPLINGS AND ADAPTERS

A. All fittings shall be provided as indicated on the Drawings. All molded fittings and fabricated fittings shall be fully pressure rated to match the pipe DR pressure rating to which they are made. All fittings shall be molded or fabricated by the manufacturer. No Contractor fabricated fittings shall be used unless approved by the Engineer.

B. The manufacturer of the HDPE pipe shall supply all HDPE fittings and accessories as well as any adapters and/or specials required to perform the work as shown on the Drawings and specified herein.

C. All fittings shall be installed using butt-fused fittings, thermo/electro fused fittings/ couplings, HDPE compatible restraint couplings (ALPHA) or mechanical flanged adapters and must be approved by the Engineer. NO size-on-size wet taps shall be permitted.

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D. All transition from HDPE pipe to ductile iron or PVC shall be made per the approval of the Engineer and per the HDPE pipe manufacturer’s recommendations and specifications. A molded flange connector adapter within a carbon steel back-up ring assembly shall be used for pipe type transitions. Ductile iron back-up rings shall mate with cast iron flanges per ANSI B16.1. A 316 stainless steel back-up ring shall mate with a 316 stainless steel flange per ANSI B16.1. HDPE compatible restraint coupling (ALPHA) is an acceptable transition device. Transition from HDPE to ductile iron fittings and valves shall be approved by the Engineer. The pipe manufacturer must certify compliance with the above requirements.

E. Butt Fusion Fittings - Fittings shall be made from HDPE pipe resin meeting ASTM D 3350 with a designation of PE 3408/PE 4710 and minimum cell classification of 445574C.

Molded Butt Fusion Fittings shall have a manufacturing standard of ASTM D-3261. Molded & fabricated fittings shall have the same pressure rating as the pipe unless otherwise specified on the plans. Fabricated fittings must have the same pressure rating as the pipe;

a DR less than the pipe shall be used. Fabricated fittings are to be manufactured using a Data Logger to record temperature, fusion pressure and a graphic representation of the fusion cycle shall be part of the Quality Control records.

F. Electrofusion Fittings - Fittings shall be made from resin or pipe meeting ASTM D 3350-05 with a minimum cell classification of 445574C.; Electro fusion Fittings shall meet the manufacturing standard of ASTM F-1055. Fittings shall have the same pressure rating as the pipe or higher unless otherwise specified on the plans.

G. HDPE Compatible Restraint Couplings - restraint couplings shall be made of materials meeting or exceeding the requirements of ASTM A536 (ductile iron). Grippers shall be ductile iron, machine sharpened and heat treated. Gaskets shall be NBR compounded for water and sewer service in accordance with ASTM D2000. For water, materials shall be NSF 61 Certified. Draw-hook fasteners, bolts and nuts shall be 304L stainless steel.

Coating shall be fusion bonded epoxy in accordance with AWWA C213. Couplings shall be pressure rated to provide a working pressure rating no less than that of the approval pipe.

Restraint couplings shall be ALPHA by Romac Industries, Inc., Hymax by Mueller or equal.

H. Flanged and Mechanical Joint Adapters - Flanged and Mechanical Joint Adapters shall be made from materials containing resin that meet ASTM D 3350 with a minimum cell classification of 445574C. Flanged and mechanical joint adapters shall have a manufacturing standard of ASTM D3216. All adapters shall be pressure rated to provide a working pressure rating no less than that of the pipe.

2.05 PIPE IDENTIFICATION

A. The following shall be continuously indent printed on the pipe or space at intervals not exceeding five (5) feet.

1. Name and/or trademark of the pipe manufacturer.

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2. Nominal pipe size.

3. Dimension ratio.

4. The letters PE followed by the polyethylene grade in accordance with ASTM.

5. D1248 followed by the hydrostatic design basis (160 psi), PE 4710.

6. Manufacturing standard reference, e.g., ASTM 714 or D3035, as required.

7. A production code from which the date and place of manufacture can be determined.

8. Color Identification, either stripped by co-extruding longitudinal identifiable color markings or shall be solid in color and as follows:

a. BLUE - Potable Water

b. GREEN - Sanitary Sewer

c. LAVENDAR - IQ cover all

B. Tracing Wire

1. Open trench installation of HDPE tracer wire shall be per Section 15020 Pressure PVC Pipe.

2. Directional Drilled HDPE shall have wire affixed to the drilling head/reamer. Tracer wire shall be Boretough Agave Extra High-Strength 1150 BLUE 12 Gauge Tracer Wire, or equal.

C. Marking Tape shall be per Specification Section 15070: Piping System Appurtenances.

PART 3 - EXECUTION

3.01 JOINING METHOD

A. The pipe shall be joined with butt, heat fusion joints as outlined in ASTM D2657 and conform to the Generic Butt Fusion Joining Procedure for Field Joining of Polyethylene Pipe, Technical Report TR-33/2005, published by the Plastic Pipe Institute (PPI). All joints shall be made in strict compliance with the manufacturer’s recommendations. A factory qualified joining technician as designated by pipe manufacturer or experienced, trained technician shall perform all heat fusion joints in the presence of the Resident Project Representative.

B. Lengths of pipe shall be assembled into suitable installation lengths by the butt-fusion process. All pipes so joined shall be made from the same class and type of raw material made by the same raw material supplier. Pipe shall be furnished in standard laying lengths

West Branch Regional Authority 02300-8 January 2026 not to exceed 50 feet and no shorter than 20 feet.

C. On days butt fusions are to be made, the first fusion shall be a trial fusion in the presence of Resident Project Representative. The following shall apply:

1. Heating plate surfaces shall be inspected for cuts and scrapes and shall be free of dirt and residue. Heater surfaces should be between 400F (minimum) to 450F (maximum). Measure the temperature @ 12:00, 3:00, 6:00 and 9:00 o’clock positions using a pyrometer of infrared thermometer at locations where the heating plate will contact the pipe/fitting ends. The maximum temperature difference between any two points on a single heating surface must not exceed 24F. If this temperature is exceeded, the heating plate shall be cleaned per the manufacturer’s recommendations.

2. The fusion or test section shall be cut out after cooling completely for inspection.

3. The test section shall be 12" or 30 times (minimum) the wall thickness in length and 1" or 1.5times the wall thickness in width (minimum).

4. The joint shall be visually inspected as to continuity of "beads" from the melted material and for assurance of "cold joint" prevention (i.e. - joint shall have visible molded material between walls of pipe). Joint spacing between the walls of the two ends shall be a minimum of 1/16" to a maximum 3/16".

D. The polyethylene flange adapters at pipe material transitions shall be backed up by stainless steel flanges conforming to ANSI B16.1 and shaped as necessary to suit the outside dimensions of the pipe. The flange adapter assemblies shall be connected with corrosion resisting bolts and nuts of Type 316 Stainless Steel as specified in ASTM A726 and ASTM A307. All bolts shall be tightened to the manufacturer’s specification. Bolts shall be tightened alternatively and evenly. After installation, apply a bitumastic coating to bolts and nuts.

3.02 INSTALLATION

A. High Density Polyethylene (HDPE) Pipe shall be installed in accordance with the instructions of the manufacturer as shown on the Drawings and as specified herein. A factory qualified joining technician as designated by the pipe manufacturer shall perform all heat fusion joints.

B. HDPE shall be installed either by Open Trench Construction or Directional Bore Method as outlined in Section 3.02 - Installation, Item Q - Open Trench Installation or Item R - Directional Bore Installation.

C. Care shall be taken in loading, transporting and unloading to prevent damage to the pipe.

Pipe or fitting shall not be dropped. All pipe or fittings shall be examined before installation

West Branch Regional Authority 02300-9 January 2026 and no piece shall be installed which is found to be defective. Any damage to the pipe shall be repaired as directed by the Engineer. If any defective pipe is discovered after it has been installed, it shall be removed and replaced with a sound pipe in a satisfactory manner by the contractor, at his own expense.

D. Under no circumstances shall the pipe or accessories be dropped into the trench or forced through a directional bore upon "pull-back".

E. Care shall be taken during transportation of the pipe such that it will not be cut, kinked or otherwise damaged.

F. Ropes, fabric or rubber protected slings and straps shall be used when handling pipes.

Chains, cables or hooks inserted into the pipe ends shall not be used. Two slings spread apart shall be used for lifting each length of pipe.

G. Pipes shall be stored on level ground, preferably turf or sand, free of sharp objects, which could damage the pipe. Stacking of the polyethylene pipe shall be limited to a height that will not cause excessive deformation of the bottom layers of pipes under anticipated temperature conditions. Where necessary due to ground conditions, the pipe shall be stored on wooden sleepers, spaced suitably and of such width as not to allow deformation of the pipe at the point of contact with the sleeper or between supports.

H. Pipe shall be stored on clean level ground to prevent undue scratching or gouging. The handling of the pipe shall be in such a manner that the pipe is not damaged by dragging it over sharp and cutting objects. The maximum allowable depth of cuts, scratches or gouges on the exterior of the pipe is 5 percent (5%) of wall thickness. The interior pipe surface shall be free of cuts, gouges or scratches.

I. Pipe shall be laid to lines and grade shown on the Drawings with bedding and backfill as shown on the Drawings.

J. When laying is not in progress, including lunchtime, the open ends of the pipe shall be closed by fabricated plugs, or by other approved means.

K. Sections of pipe with cuts, scratches or gouges exceeding 5 percent (5%) of the pipe wall thickness shall be removed completely and the ends of the pipeline rejoined.

L. The pipe shall be joined by the method of thermal butt fusion, as outlined in PART 3 -

EXECUTION, SECTION 3.01 JOINING METHOD. All joints shall be made in strict compliance with the manufacturer’s recommendations.

M. Mechanical connections of the polyethylene pipe to auxiliary equipment such as valves, pumps and tanks shall be through flanged connections which shall consist of the following:

1. A polyethylene flange shall be thermally butt-fused to the stub end of the pipe.

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2. A 316 stainless steel back up ring shall mate with a 316 stainless steel flange.

3. Stainless steel bolts and nuts shall be used.

4. Other methods with approval by Owner and Engineer.

N. Flange connections shall be provided with a full-face neoprene gasket.

O. All HDPE pipe must be at the temperature of the surrounding soil at the time of backfilling and compaction.

P. If a defective pipe is discovered after it has been installed, it shall be removed and replaced with a sound pipe in a satisfactory manner at no additional cost to the Owner. All pipe and fittings shall be thoroughly cleaned before installation, shall be kept clean until they are used in the work and when laid, shall conform to the lines and grades required.

Q. Open Trench Installation:

1. Specification, Section 02205: Earthwork for Pipelines shall apply in its entirety.

2. The centerline of the pipe shall not deviate from a straight line drawn between the centers of the openings at the ends of the pipe by more than 1/16-in per foot of length. If a piece of pipe fails to meet this requirement check for straightness, it shall be rejected and removed from the site. Laying instructions of the manufacturer shall be explicitly followed.

3. Good alignment shall be preserved during installation. Deflection of the pipe shall occur only at those places on design drawings and as approved by the Engineer.

Fittings, in addition to those shown on the Drawings, shall be used only if necessary or required by the Engineer.

4. Each length of the pipe shall have the assembly mark aligned with the pipe previously laid and held securely until enough backfill has been placed to hold the pipe in place. Joints shall not be "pulled" or "cramped".

5. Precautions shall be taken to prevent flotation of the pipe in the trench.

6. When moveable trench bracing such as trench boxes, moveable sheeting, shoring or plates are used to support the sides of the trench, care shall be taken in placing and moving the boxes or supporting bracing to prevent movement of the pipe, or disturbance of the pipe bedding and the backfill. Trench boxes, moveable sheeting, shoring or plates shall not be allowed to extend below top of the pipe. As trench boxes, moveable sheeting, shoring or plates are moved, pipe bedding shall be placed to fill any voids created and the backfill shall be re-compacted to provide uniform side support for the pipe.

7. Restrained joints shall be installed where shown on the Drawings or as directed by

West Branch Regional Authority 02300-11 January 2026 the Engineer.

R. Directional Bore Installation:

1. Refer to Specification Section 02310: Horizontal Directional Drilling in its entirety.

3.03 CLEANING

A. At the conclusion of the work, thoroughly clean all of the new pipe lines to remove all dirt, stones, pieces of wood or other material which may have entered during the construction period by forcing a cleaning swab through all mains 4" or greater. Flushing velocities shall be a minimum of 2.5 feet per second. All flushing shall be coordinated with Resident Project Representative and the Owner. Debris cleaned from the lines shall be removed from the job site.

3.04 TESTING

A. Pressure testing shall be conducted per manufacturer’s recommendations and as approved by the Engineer. Also refer to Appendix No. 1.

B. All HDPE mains shall be field-tested. Contractor shall supply all labor, equipment, material, gauges, pumps, meters and incidentals required for testing. Each main shall be pressure tested upon completion of the pipe laying and backfilling operations, including placement of any required temporary roadway surfacing.

C. All mains shall be tested at 1.5 times the operating design pressure of the pipe unless otherwise approved by the Engineer.

D. Pressure testing procedure shall be per manufacturer’s recommendations or as follows:

1. Fill line slowly with water. Maintain flow velocity less than 2 feet per second.

2. Expel air completely from the line during filling and again before applying test pressure. Air shall be expelled by means of taps at points of highest elevation.

3. Apply initial test pressure and allow to stand without makeup pressure for two to three hours, to allow for diametric expansion or pipe stretching to stabilize.

4. After this equilibrium period, apply the specified test pressure and turn the pump off. The final test pressure shall be held for one to three hours.

5. Upon completion of the test, the pressure shall be bled off from a location other than the point where the pressure is monitored. The pressure drop shall be witnessed by the Resident Project Representative and the Owner representative at the point where the pressure is being monitored and shall show on the recorded

West Branch Regional Authority 02300-12 January 2026 pressure read-out submitted to the Engineer of Record.

E. Allowable amount of makeup water for expansion during the pressure test shall conform to

Chart 6, Allowance for Expansion Under Test Pressure, Technical Report TR 31/9-79, published by the Plastic Pipe Institute (PPI). If there are no visual leaks or significant pressure drops during the final test period, the installed pipe passes the test.

F. If any test of pipe laid disclosed leakage significant pressure drop greater than the manufacturer’s recommended loss, the Contractor shall, at his own expense, locate and repair the cause of leakage and retest the line. The amount of leakage, which will be permitted, shall be in accordance with AWWA C600 Standards.

G. All visible leaks are to be repaired regardless of the amount of leakage.

H. The Contractor must submit his plan for testing to the Engineer for review at least ten (10) days before starting the test and shall notify the Resident Project Representative and the Owner a minimum of 48 hours prior to test.