SANS1200L

© SABS.
This standard may reside on a LAN, WAN, intranet, internet or ECM server and is exclusively available to subscribers to the SABS’ Complete Collection
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S A B S 1 2 C O L-1983
SOUTH A F R I C A N BUREAU O F STANDARDS
STANDARDIZED S P E C I F I C A T I O N
€or
C I V I L ENGINEERING CONSTRUCTION
L : MEDIUM-PRESSURE PIPELINES
A p p r o v e d by t h e O b t a i n a b l e from t h e
C O U N C I L OF T H E S A BUREAU O F STANDARDS
SOUTH A F R I C A N P r i v a t e Bag X191
BUREAU O F STANDARDS Pretoria
o n 2 March 1983 0001 R e p u b l i c of South A f r i c a
Telegrams : Comparator, P r e t o r i a
COPYRIGHT RESERVED
P u b l i s h e d and p r i n t e d i n t h e R e p u b l i c of South A f r i c a by t h e
South A f r i c a n Bureau of S t a n d a r d s
ISBN 0-626-06424-4 Gr 7
© SABS. This standard may only be used and printed by subscribers to the SABS’ Complete Collection of Standards and Related Documents.
© SABS. This standard may reside on a LAN, WAN, intranet, internet or ECM server and is exclusively available to subscribers to the SABS’ Complete Collection
3 SABS 1%(111 .I 1983
Medium-pressure p i p e 1 ities
CONTENTS
Clause rage Number
1 . SCOPE .............................................................................. 5
2 . INTERPRETATIONS .................................................................... 5
2.1 References ......................................................................... 5
2.1.1 ................ ..................................................
Code o f p r a c t i c e 5
2.1.2 ....... ..................................................
Supporting s p e c i f i c a t i o n s 5
2.2 Application ..................... .................................................. 5
2.3 Defini.tions ..................... .................................................. 5
2.4 Abbreviations ................... .................................................. 5
3 .3.1 MATERIALS ....................... .................................................. 5
General ......................... .................................................. 5
3.2 ........... ..................................................
AC P i p e s and S p e c i a l s 5
3.3 ..................................................
CI P i p e s . F i t t i n g s . and S p e c i a l s 5
3.4 ................................................
S t e e l P i p e s . F i t t i n g s . and S p e c i a s 6
3.4.1 General ......................... .................................................. 6
3.4.2 .................................................
P i p e s o f nominal b o r e u p t o 150 mm 6
3.4.3 ..................................................
P i p e s of nominal b o r e o v e r 150 mm 6
3.4.4 ..............................................................
F i t t i n g s and s p e c i a l s 6
3.5 Concrete P r e s s u r e Pipes............................................................ 6
3.6 .........................................................
P r e s t r e s s e d Concrete Pipes 6
3.7 ...............................................................
O t h e r Types o f P i p e s 6
3.7.1 .........................................................................
UPVC p i p e s 6
3.1.2 Polyethylene p i p e s ................................................................. 6
3.8 .................................................................
J o i n t i n g Materials 6
3.8.1 _ - ...........................................................................
AC u i u e s
Flexible couplings ......... .......................................................
6
6
3.8.2
3.8.3 F l a n g e s and accessories .... ....................................................... 6
3.8.4 .............. .......................................................
Loose f I a n g e s 6
3.8.5 ............ .......................................................
Spigot s p e c i a l s 6
3.8.6 .... .......................................................
S p i g o t and s o c k e t p i p e s 6
3.8.7 Screw-ended p i p e s .......... ....................................................... 7
3.9 corrosion Protection ....... ....................................................... 7
3.9.1 ................... .......................................................
CI p i p e s 7
3.9.2 ................ .......................................................
Steel p i p e s 7
3.9.3 Protection aqainst electroly ic corrosion .......................................... 7
3.9.4 F l e x i b l e c o u. ......... .......................................................
p l i n g.s 7
3.9.5 ...................................................
J o i n t s , b o l t s . n u t s . and w a s h e r s 7
3.9.6 corrosive soil ..................................................................... 7
3.10 Valves ............................................................................. 7
3.11 Manholes and S u r f a c e Boxes ......................................................... 8
3.11.1 Bricks ............................................................................. 8
3.11.2 Precast cylinders .................................................................. 8
3.11.3 Concrete ........................................................................... 8
3.11.4 Step irons ......................................................................... 8
3.11.5 ..........................................................
Manhole c o v e r s and f r a m e s 8
3.11.6 Sur f a c e boxes...................................................................... 8
4 . PLANT .............................................................................. 8
4.1 ...............................................................
B a n d l i n g and R i g g i n g 8
4.2 ........................................................................
S e t t i n g Out 8
4.3 Testing ............................................................................ 8
5 . CONSTRUCTION ....................................................................... 8
5.1 Laying ............................................................................. 8
5.1.1 General ............................................................................ 8
5.1.2 Damage ............................................................................. 8
5.1.3 ............................................................
Keeping p i p e l i n e s c l e a n 8
5.1.4 DeDths and c o v e r................................................................... 8
5.2 ..................................
J o i n t i n g Methods ................................
...... ................................
D e t a c h a b l e c o u p l i n g s (AC and uPVC p i p e l i n e s )
9
5.2.1 9
5.2.2 .........................
Flanges (steel p i p e l i n e s ) ................................ 9
5.2.3 Welding (steel p i p e l i n e s of diameter 600 am or g r e a e r )............................ 9
5.2.4 .............. ................................
C o n c r e t e s p i g o t and s o c k e t p i p e l i n e s 9
5.3 ......... ................................
S e t t i n g of Valves. Spe c ia ls . and F i t t i n g s 9
5.4 Concrete Casing ................................... ..... ..........................
; 9
5.5 ................ ................................
A n c h o r / T h r u s t B l o c k s and P e d e s t a l s 10
5.6 Valve and H y d r a n t Chambers........................ ................................ 10
5.6.1 General ........................................... ................................ 10
5.6.2 ..........................
C o n s t r u c t i o n of chambers ................................ 10
5.7 Manholes ........................................................................... 10
5.7.1 General ............................................................................ 10
5.7.2 ...................................................................
P r e c a s t manholes 10
5.8 Brickwork i n Chambers and Manholes ................................................. 10
5.9 .............................................
L i f t i n g and R e l a y i n g of E x i s t i n g P i p e s 10
5.10 ............................................
D i s i n f e c t i o n o f P o t a b l e Water P i p e l i n e s 10
6 .6.1 TOLERANCES
General
.........................................................................
............................................................................
11
11
6.2 .....................................................................
Control P o i n t s 11
6.3 .........................................................
Alignment ( P l a n and L e v e l ) 11
6.4 Manholes. V a l v e Chambers. e t c...................................................... 11
SABS 1200 L-1'183 4
Mediuai-pressure p i p e 1 i n m
Clause Page Clumber

l__l_
7 . Testing ............................................................................ 11
7.1 General ............................................................................ 11
7.2 ................................................
I n i t i a l 'ksts O I I Welded S t e e l P i p e s 1.1
7.2.1 Dye-penetrant test ................................................................. ~1
7.2.2 Radiographic examination ........................................................... 11
7*3 Standard Hydraulic Pipe T e s t ....................................................... 11
7.3.1 .....................................................
T e s t pressure a n d t i m e o f t e s t 11
7.3.2 Visible leaks ...................................................................... 1~
7.3.3 ..........................................................
P e r m i s s i b l e l e a k a g e ra t e s 1~
7.4 ............................................................
T e s t s on Epoxy C o a t i n g s 12
8 . MEASIJREMEN'C AND PAYMENT ............................................................ 1~
8.1 General ............................................................................ 1~
8.2 ....................................................................
S c t r e d u l e d Items 12
DRAWINGS
Drawing I.. 1 .D e t a i l ..........- 1 4

of V a l v e Chamber f o r a V a l v e of Nominal B o r e n o t e x c e e d i n g 200 m
Drawing L-2 .Det.ai1 .................................................... 1~
of B r i c k H y d r a n t Chamber
Drawing L-3 o f P r e c a s t H y d r a n t Chamber ..................................................
.Detail 16
APPENDIX A . APPLICABLE STANDARDS ................................................................. 17
F i r s t R e v i s i o n March 1 9 8 3
This specification supersedes
SABS 1200 L-1980
5 SNF; 1200 L-19135
Medium-pressure pipelines
SO~ITIIAFRICAN BUREAU OF STANDARDS
STANDARDIZED SPECIFICATION
for
CIVIL ENGINEER3NG CONSTRUCTION
L : MEDIUM-PRESSURE PIPELINES
1. SCOPE
1.1 This specification covers the supply and installation of pipelines of diameter up to 1 000 mm, Complete
wit.h ancillary works, for transporting water and sewage under working pressures of up to 2 . 5 MPa.
NOTE: The standards referred to in the specification are listed in Appendix A.
2. INTF:RPHETATIONS
2.1 REFERENCES
2.1.1 Code of Practice. The recommendations of SABS 0102 have been incorporated into this specification in SC’
far as they are applicable.
2.1.2 Supporting Specifications. Where this specification is required for a project, the following specifi-
cations shall, inter alia, form part of the contract document:
a) Project specification;
b) SABS 1200 A or SABS 1200 AA, as applicable;
c) SARS 1200 D or SABS 1200 DA, as applicable;
d) SARS 1200 DB;
e) SAHS 1200 G or SABS 1200 GA, as applicable;
f) SABS 1200 1.B;
9) SABS 1200 LK.
2.2 APPLICATION. This specification contains clauses that are generally applicable to medium-pressure
pipelines. Interpretations and variations of this specification are set out in Portion 2 of the project
specification which precedes this specification in a contract document.
2.3 DEFINITIONS. For the purposes of this specification the definitions given in the applicable of the
specifications listed in 2.1.2(b)-(g) ajid the following definitions shall apply:
Fitting
a) A special or valve.
b) Any process of jointing (except welding) straight pipes to one another and to specials and valves.
Special. Any pipe other than a straight pipe.
NOTE: Under this definition are included all sizes of specials such as bends, tees, crosses, angle
branches, reducers, and tapers.
Straight pipe. A straight pipe of uniform bore and of standard or non-standard length.
2.4 ABBREVIATIONS. For the purposes of this specifj.cation the abbreviations given in the applicable of the
specifications listed in 2.1.2(b)-(g) and the following abbreviations shall apply:
AC : Asbestos cement
CI : Cast iron
CID : Constant internal diameter
COD : Constant outside diameter
IRHD : International rubber hardness degrees
PTFE : Polytetrafluoro ethylene
PVC : Po1yvinp.l chloride
UPVC : Unplasticized polyvinyl chloride
3. MATER.LALS
3.1 tiENERAL. Pipes and fittings shall be of the types specified in the schedule or in the project
specification and, unless otherwise required in terms of the project specification, they and their
couplings shall be capable of withstanding the applicable test pressure specified in 7.3.1. All pipes
and fittings shall be supplied complete with couplings and jointing material.
Satisfactory temporary end covers shall be provided for the protection of threads, flanges, and prepared
ends of plain-ended pipes and fittings, and to prevent damage to internal lining during transportation
and during handling 0 1 1 Site.
Pipeline materials shall be so transported, stored, and handled that pipes are not overstressed at any
time and fittinqs are not damaged in any way. All thin-walled, flexible, and soft-coated pipes shall be
handled with particular care and shall be so stored that they are not subject to concentrated pressure
from stones or other objects. Pipes damaged or cracked in any way shall be removed from the Site.
3.2 AC PIPES AND SPECIALS. AC pipes shall comply with the requirements of SABS 286 for COD pipes or SABS 946
for CID pipes. COD pipes shall be used for all sizes up to and including 200 mm diameter unless
otherwise scheduled or stated in the project specification. A? pipes shall be bitumen-dipped if so
required in terms of the project specification. (See 3.8.1 for jointing materials.)
Specials for use with an AC pipeline, whether of AC, CI, or steel, shall be rated at not less than the
pressure rating of the pipeline.
3.3 C1 PIPES, FITTINGS, AND SPECIALS. CI pipes and flanged fittings shall comply with the applicable
requirements OC HS 2035.
CI fittings and special fittings for use with AC pipes shall comply with the applicable requirements of
SABS 546.
S A B S 1200 L-1383 6
Medium-pressure p i p e 1 i n e s
3.4 s m E L PIPES, FITTINGS, AND SPECIAIS

3.4.1 G e n e r a l . The C o n t r a c t o r s h a l l , i f so i n s t r u c t e d , make a v a i l a b l e to t h e Etiyinrer t h e m . l k c r ' s c : e r t i f i . r a t r s
.
I
-
c o v c r i n g t h e c h e m i c a l a n a l y s i s and p h y s i c a l p r o p e r t i e s o f t h e steel u s e d i n t h e manufact-.ure of p i p e s and
s p e c i a l s , and s h a l l p r o v i d e w r i t t e n c o n f i r m a t i o n t h a t w e l d i n g h a s been c a r r i e d o u t b y coded w e l d e r s .
3.4.2 P i p e s o f Nominal Bore up t o 150 mm. U n l e s s o t h e r w i s e s c h e d u l e d or r e q u i r e d i n terms o f t h e p r o j e c t
s p e c i f i c a t i o n , s t e e l p i p e s and f i t t i n g s o f nominal b o r e u p t o 150 mm s h a l l be o f medium class, s h a l l b e
screwed, and s h a l l comply w i t h t h e a p p l i c a b l e r e q u i r e m e n t s o f SABS 6 2 .
3.4.3 P i p-
- es - o f Womirial Bore o v e r 150 mn. S t e e l p i p e s o f nominal b o r e o v e r 150 mm s h a l l comply w i t h t h e
a p p l i c a b l e r e q u i r e m e n t s o f SABS 719 a p p r o p r i a t e t o t h e g r a d e o f p i p e s c h e d u l e d or s p e c i f i e d i n t h e
p r o j e c t s p e c i f i c a t i o n and, i n a d d i t i o n ,
a ) t h e minimum w a l l t h i c k n e s s s h a l l be 4 mm f o r p i p e s o f nominal o u t s i d e diameter n o t e x c e e d i n g 400 min.
and 5 mm f o r p i p e s o f nominal o u t s i d e diamet-er e x c e e d i n g 400 mm b u t n o t e x c e e d i n g 500 mm:
b ) t h e p i p e s s h a l l b e p l a i n ended and of one f i x e d l e n g t h between 3 ni and 18 m; and
c) t h e h e i g h t o f i n n e r weld r e i n f o r c e m e n t and o f u p s e t metal on t h e i n n e r s u r f a c e s h a l l n o t e x c e e d 1 mm.
3.4.4 F i t t i n g s and S p e c i a l s . S t e e l p i p e f i t t i n g s and s p e c i a l s o f nominal b o r e l a r g e r t h a n 150 mm s h a l l b e
f a b r i c a t e d i n a c c o r d a n c e w i t h BS 534 from p i p e complying w i t h t h e r e q u i r e m e n t s g i v e n i n 3 . 4 . 3 . In
a d d i t i o n , a l l p i p e s p e c i a l s and f i t t i n g s s h a l l b e f r e e o f weld s p a t t e r and a l l s h a r p c o r n e r s and e d g e s
s h a l l b e ground smooth and round b e f o r e p a i n t i n g .
A l l s h o p weldiny o f s l i p - o n and o t h e r c o u p l i n g s f o r steel p i p e s and s p e c i a l s s h a l l b e c a r r i e d o u t by
w e l d e r s who are competent i n terms o f t h e p r o c e d u r e a p p r o v a l test o f AP1 1104, e x c e p t where t h e p r o j e c t
s p e c i f i c a t i o n makes p r o v i s i o n f o r a n o t h e r competence t e s t t o b e a g r e e d between t h e E n g i n e e r and t h e
Contractor.
3.5 CONCRETE PRESSURE PIPES. U n l e s s o t h e r w i s e s c h e d u l e d , c o n c r e t e p r e s s u r e p i p e s s h a l l comply w i t h t h e

r e q u i r e m e n t s o f SABS 676 a p p r o p r i a t e t o t h e p r e s s u r e c l a s s s t a t e d i n t h e s c h e d u l e and s h a l l have s p i g o t
and socket e n d s w i t h r u b b e r r i n g j o i n t s or o t h e r approved f l e x i b l e j o i n t s .
3.6 PRESTRESSED CONCRETE PIPES. P r e s t r e s s e d c o n c r e t e p i p e s s h a l l comply w i t h t h e r e q u i r e m e n t s o f S A W 975

and t h e nominal i n t e r n a l d i a m e t e r , t h e nominal e f f e c t i v e l e n g t h , t h e h y d r a u l i c t e s t p r e s s u r e , and t h e
p r o o f l o a d s h a l l b e as s t a t e d i n t h e p r o j e c t s p e c i f i c a t i o n . The C o n t r a c t o r s h a l l s u p p l y t h e i n f o r m a t i o n
d e t a i l e d i n Appendix :E t o SABS 975 when so r e q u e s t e d by t h e E n g i n e e r .
Metal c o u p l i n g s o f a l l t y p e s and t h e means u s e d f o r d i s t r i b u t i n g c o u p l i n g stresses t o t h e c o n c r e t e s h a l l
b e c a p a b l e of w i t h s t a n d i n g a l l stresses c a u s e d by p r o p e r t i g h t e n i n g o f t h e b o l t s w i t h o u t any s i g n o f
c r a c k i n g or o t h e r damage.
3.7 OTHER TYPES OF PTPES

3.7.1 _____
uPVC P i p e s . uPVC p i p e s and f i t t i n g s s h a l l b e f i t t e d w i t h s p i g o t and s o c k e t r u b b e r r i n g j o i n t s and s h a l l
comply w i t h t h e r e l e v a n t r e q u i r e m e n t s o f SABS 966.
3.7.2 Polyethylene Pipes. P o l y e t h y l e n e p i p e s and f i t t i n g s ' s h a l l comply w i t h t h e r e l e v a n t r e q u i r e m e n t s of
SABS 533.
3.8 JOINTING MATERIALS

3.8.1 -
AC-
Pipes. AC p i p e s s h a l l b e j o i n t e d t o e a c h o t h e r by means o f AC 3 - r i n g s l e e v e - t y p e c o u p l i n g s complying
w i t h t h e r e l e v a n t r e q u i r e m e n t s o f BS 486. U n l e s s o t h e r w i s e s c h e d u l e d or shown on t h e d r a w i n g s , AC p i p e s
s h a l l b e j o i n t e d to v a l v e s w i t h s t a n d a r d C I s h o r t c o l l a r d e t a c h a b l e c o u-p l i n q- s .
3.8.2 -___
F l e x i b l e Couplings
3.8.2.1 Except where s p e c i a l c o u p l i n g s are s c h e d u l e d , f l e x i b l e c o u.~ _ _
p l i n g s f o r p l a i n - e n d e d steel pipe s h a l l b e o f
t h e s l i p - o n t y p e w i t h c e n t r e r e g i s t e r complying w i t h t h e r e l e v a n t r e q u i r e m e n t s o f B s 534.
3.8.2.2 A c o u p l i n g s h a l l b e a b l e to w i t h s t a n d w i t h o u t any s i g n o f f a i l u r e a h y d r o s t a t i c t e s t p r e s s u r e o f t w i c e
t h e working p r e s s u r e s p e c i f i e d f o r t h e p i p e f o r which t h e c o u p l i n g i s r e q u i r e d .
3.8.2.3 Coupling f l a n g e s s h a l l b e c a p a b l e o f w i t h s t a n d i n g w i t h o u t a n y s i g n o f damage a l l stresses c a u s e d by
proper tightening of t h e b o l t s .
3.8.2.4 Rubber r i n g s s h a l l comply w i t h t h e r e l e v a n t r e q u i r e m e n t s of SABS 974 : P a r t I and s h a l l h a v e a h a r d n e s s
o f 66-75 I R H D .
3.8.3 F l a n g e s a n d c c e s s o r i e s _ . Each f l a n g e d p i p e and f i t t i n g s h a l l be s u p p l i e d c o m p l e t e w i t h one set o f b o l t s
and n u t s and one i n s e r t i o n p i e c e o f t h e a p p r o p r i a t e d i a m e t e r and made o f a material t h a t i s s u i t a b l e f o r
t h e maximum t e s t p r e s s u r e . The d r i l l i n g o f steel and C I f l a n g e s s h a l l conform to t h e r e q u i r e m e n t s of
S A R S 1123 or BS 4504 : P a r t 1 , as a p p l i c a b l e , a p p r o p r i a t e t o t h e class o f p i p e s p e c i f i e d , e x c e p t t h a t
a) i n t h e case o f f l a n y e s for h y d r a n t a n d a i r v a l v e matching tees, t h e d r i l l i n g s h a l l conform to t h e
d r i l l i n g o f t h e v a l v e s u p p l i e d , and
b ) i n t h e case of C 1 f l a n g e s , where M27 and M33 b o l t s are s p e c i f i e d i n BS 4504 : P a r t 1 , M24 and M30
b o l t s r e s p e c t i v e l y s h a l l b e u s e d as s p e c i f i e d i n SARS 1123.
3.8.4 Loose F l a n g e s . Loose f l a n g e s f o r w e l d i n g o n t o steel p i p e s on S i t e s h a l l b e m a n u f a c t u r e d from t h e same
steel as i s s p e c i f i e d f o r t h e p i p e s and s h a l l b e i n a c c o r d a n c e w i t h SABS 1123 (see also 3 . 4 . 3 ) . Any i t e m
o f pipework t h a t is found t o have f l a n g e s t h a t are i n c o r r e c t l y d r i l l e d w i l l b e r e j e c t e d . Reaming o f b o l t
h o l e s t o o v e r s i z e d i m e n s i o n s i n o r d e r t o make a p a r t . i c u l a r p i e c e f i t w i l l n o t b e p e r m i t t e d .
B o l t s and n u t s s h a l l comply w i t h t h e r e l e v a n t r e q u i r e m e n t s o f SABS 135 o r SABS 136, a s s p e c i f i e d i n t h e
project specification. The l e n g t h o f e a c h b o l t s h a l l b e s u c h t h a t , a f t e r t h e b o l t h a s been t i g h t e n e d ,
t h e end o f t h e b o l t i s f l u s h w i t h t h e o u t s i d e o f t h e n u t or p r o j e c t s above t h e n u t by n o t more t h a n t w o
f u l l threads.
3.8.5 *got S p e c i a l s . Each s p i g o t e d s p e c i a l s h a l l b e s u p p l i e d w i t h one s l e e v e c o u p l i n g (or s u c h o t h e r tyj>e o f
c o u p l i n g a s i s shown i n t h e d r a w i n g s ) to s u i t t h e p a r t i c u l a r p i p e w i t h which t h e s p e c i a l is t o mate. The
c o u p l i n g s h a l l f i t t h e l a r g e r end o f t h e b a r r e l i n t h e case o f a r e d u c e r .
3.R.6 S p i g o t and S o c k e t P i p e s . S p i g o t and socket p i p e s s h a l l b e p r o v i d e d w i t h r u b b e r or neoprene s e a l i n g r i n g s
f o r forming f l e x i b l e c o u p l i n g s o r , where so r e q u i r e d i n terms o f t h e p r o j e c t s p e c i f i c a t i o n , c a u l k i n g
materials s h a l l b e p r o v i d e d .
7 SABS 1200 L-1983
Medium-pressure p i p e l i n e s
3.8.7 _________
Screw-Ended P i p e s . Screw-ended p i p e s s h a l l comply w i t h t h e r e l e v a n t r e q u i r e m e n t s of SABS 110'9. Male
e n d s s h a l l b e t a p e r - s c r e w e d and f e m a l e e n d s s h a l l have p a r a l l e l t h r e a d s .
3.9 CORIIOS ION FR(YPl?CTION

3.9.1 CI P i p e s . With t h e e x c e p t i o n o f f l a n g e f a c e s and e x t e r n a l s u r f a c e s t h a t are t o be s e t i n corlcrete and
e x c e p t where o t h e r w i s e r e q u i r e d i n terms o f t h e p r o j e c t s p e c i f i c a t i o n , C I p i p e s , s p e c i a l s , and h y d r a n t s
s h a l l b e c l e a n e d and t h e n c o a t e d e x t e r n a l l y and i n t e r n a l l y i n a c c o r d a n c e w i t h US 4772. A f t e r i t h a s set.
t h e c o a t i n g s h a l l b e s u c h t h a t it w i l l n o t f l o w when h e a t e d t o a t e m p e r a t u r e of 75 OC.
3.9.2 Steel Pipes
______
3.9.2.1 S t e e l p i p__ e s o-f nominal b o r e u p t o 150 mm. E x c e p t where, b e c a u s e o f t h e s i z e or s h a p e o f t h e i t e m s ,
d i p p i n g i s i m p r a c t i c a b l e , steel p i p e s and f i t t i n g s , i n c l u d i n g f l a n g e s and s p e c i a l s , o f nominal b o r e uj3 t o
and i n c l u d i n c ~150 mm s h a l l have a c o a t i n g o f z i n c a p p l i e d i n t e r n a l l y and e x t e r n a l l y by t h e h o t - d i p
p r o c e s s and complying w i t h t h e r e l e v a n t r e q u i r e m e n t s o f SABS 763, or t h e y s h a l l b e c o a t e d i n t e r n a l l y and
c x t e r n a l l y w i t h bitumen or o t h e r approved material s u i t a b l e f o r u s e i n d o m e s t i c water m a i n s , a s r e q u i r e d
i n terms o f t h e s c h e d u l e .
Items t h a t are n o t d i p p e d s h a l l b e s h o p p a i n t e d .
3.9.2.2 S t e e l p i p e s o f nominal b o r e o v e r 150 nun. S t e e l p i p e s , f i t t i n g s , f l a n g e s , and s p e c i a l s o f nominal b o r e
_______-__
o v e r 150 mm s h a l l have t h e i r s u r f a c e s t h o r o u g h l y c l e a n e d by g r i t b l a s t i n g t o a f i n i s h complying w i t h t h e
r e q u i r e m e n t s o f SIS 05 59 00 f o r a n Sa 23 f i n i s h and s h a l l , w i t h i n 4 h a f t e r c l e a n i n g , b e primed w i t h t h e
p r i m e r s p e c i f i e d below o r , i f no p r i m e r is s p e c i f i e d , w i t h a p r i m e r o f a n approved t y p e , and p r o v i d e d
w i t h o n e of t h e f o l l o w i n g forms o f p r o t e c t i o n , as s c h e d u l e d or as r e q u i r e d i n terms o f t h e p r o j e c t
s p e c i f i c a t i o n:
NOTE
i) A s f a r as i s p r a c t i c a b l e , t h e h a n d l i n g o f c l e a n e d articles a f t e r g r i t b l a s t i n g and b e f o r e any c o a t i n g
is a p p l i e d , s h a l l h e a v o i d e d .
i i ) Materials o f p i p e l i n i n g s y s t e m s f o r p i p e s i n t e n d e d t o convey p o t a b l e water s h a l l be n o n - t o x i c .
a) Bitumen c o a t i n g and l i n i n g a p p l i e d by
1 ) i n t h e c a s e o f t h e l i n i n g , s p i n n i n g t o a n a v e r a g e t h i c k n e s s o f 3.0 mm (minimum t h i c k n e s s 2.5 mm) w i t h
bitumen complying w i t h t h e r e q u i r e m e n t s o f SABS 1137; a n d
2) i n t h e case o f t h e c o a t i n g , wrappinq w i t h a d o u b l e l a y e r o f bitumen-impregnated g l a s s f i b r e complying
w i t h t h e r e q u i r e m e n t s f o r Type 1 of SABS 1130 t o form a c o a t i n g o f a v e r a g e t h i c k n e s s 5 mm a n d o f minimum
t h i c k n e s s 4.5 mm and, o n c o m p l e t i o n of t h e c o a t i n g , w h i t e washing of t h e s h e a t h i n g .
b ) C o a t i n g and l i n i n q u s i n q , s u b j e c t t o a p p r o v a l , one o f t h e f o l l o w i n g epoxy systems:
1 ) The a p p l i c a t i o n o f a n epoxy p r i m e r , f o l l o w e d by o n e or more coats o f h i g h - b u i l d epoxy material t o g i v e
a t o t a l d r y f i l m t h i c k n e s s o f a t l e a s t 250 pm, e a c h coat h a v i n g a c o l o u r d i f f e r e n t from t h a t o f i t s
p r e d e c e s s o r and a p p l i e d n o t less t h a n 6 h and n o t more t h a n 24 h a f t e r i t , care b e i n g t a k e n t o e n s u r e
t h a t t h e p r e v i o u s coat h a s d r i e d s u f f i c i e n t l y t o p r e v e n t s o l v e n t e n t r a p m e n t .
2) A polyamide-cured epoxy s y s t e m c o n s i s t i n g o f a t l e a s t t h r e e coats t o g i v e a t o t a l d r y f i l m t h i c k n e s s
o f a t l e a s t 250 pm, w i t h o u t h o l i d a y s , t h e f i r s t c o a t ' b e i n g a p p l i e d as a p r i m e r i m m e d i a t e l y a f t e r grit
b l a s t i n g arid s u b s e q u e n t coats n o t less t h a n 6 h and n o t more t h a n 24 h a f t e r t h e p r e v i o u s coat, care
b e i n g t a k e n t o e n s u r e t h a t t h e p r e v i o u s coat h a s d r i e d s u f f i c i e n t l y t o p r e v e n t s o l v e n t e n t r a p m e n t .
3) A s o l v e n t - f r e e h o t coat epoxy w i t h a d r y f i l m t h i c k n e s s of a t l e a s t 250 pm, and w i t h o u t h o l i d a y s .
4 ) A powder ( s i n t e r e d ) epoxy c o a t i n g w i t h a d r y f i l m t h i c k n e s s o f a t l e a s t 250 urn, and w i t h o u t h o l i d a y s .
c) C o n c r e t e l i n i n g or c o a t i n g , or b o t h , complying w i t h t h e a p p l i c a b l e r e q u i r e m e n t s o f t h e p r o j e c t
specification.
3.9.2.3 -
R e p a i r s t o epoxy c o a t i n g s . When a n epoxy c o a t i n g i s t e s t e d i n a c c o r d a n c e w i t h 7 . 4 ( a ) - ( c ) and i n
a c c o r d a n c e w i t h a n y o t h e r test c a r r i e d out i n terms o f 7 . 4 ( d ) ,
a ) any area i n which p i n h o l e s or h o l i d a y s are d e t e c t e d s h a l l , i n t h e case of l a r g e d i a m e t e r p i p e s , b e
t h o r o u g h l y a b r a d e d w i t h w a t e r p r o o f p a p e r , m o i s t e n e d w i t h a n approved s o l v e n t , wiped c l e a n , and r e c o a t e d
t o t h e s a t i s f a c t i o n o f tlio Engineer a n d , i n t h e case o f p i p e s o f d i a m e t e r too s m a l l f o r s u c h r e p a i r s t o
b e c a r r i e d o u t , r e p a i r s s h a l l b e e f f e c t e d by o v e r c o a t i n g w i t h a n o t h e r coat o f epoxy;
b ) any c o a t i n g t h e t h i c k n e s s of which d o e s n o t comply w i t h t h e a p p l i c a b l e r e q u i r e m e n t s o f 3.9.2.2Cb) b u t
which i s o t h e r w i s e sound, s h a l l have one or more a d d i t i o n a l coats a p p l i e d ;
c) any c o a t i n g t h a t e x h i b i t s i n a d e q u a t e c u r i n g s h a l l , if p r a c t i c a b l e , b e p r o p e r l y c u r e d or t h e c o a t i n g
s h a l l be removed and a new c o a t i n g a p p l i e d , as o r d e r e d by t h e E n g i n e e r ;
d ) any c o a t i n g found t o b e d e f e c t i v e i n t e r m s o f t h e r e s u l t s o f a t e s t or tests c a r r i e d o u t i n a c c o r d a n c e
w i t h 7 . 4 ( d ) s h a l l b e r e p i i r e d or t h e c o a t i n g s h a l l be t r e a t e d as i n (a) above, as o r d e r e d by t h e
Engineer.
3.9.3 P r o t e c t i o n a g a i n s t E l e c t r o l y t i c Corrosion. External protection a g a i n s t e l e c t r o l y t i c corrosion,
c o n s i s t i n g o f a n e x t r u d e d s h e a t h o f poly!vinyl c h l o r i d e or p o l y e t h y l e n e , an i m p e r v i o u s a d h e s i v e p l a s t i c s
t a p e o r petroleum-base impregnated t a p e , or o t h e r approved i n s u l a t i n g m a t e r i a l , s h a l l b e a p p l i e d i n
a d d i t i o n t o , or i n s t e a d o f . a n y o f t h e p r o t e c t i v e c o a t i n g s s p e c i f i e d i n 3 . 9 . 1 and 3.9.2, as and where
r e q u i r e d i n terms o f t h e p r o j e c t s p e c i f i c a t i o n .
3.9.4 F l e x i b l e coupling^.. F l e x i b l e c o u p l i n g s f o r steel p i p e s s h a l l b e t h o r o u g h l y c l e a n e d and t h e n p a i n t e d as
s p e c i f i e d i n 3.9.2.2(b) ( 1 ) .
3.9.5 J o i n t s , Dolts, N u t s , and Washers. Where no o t h e r p r o t e c t i o n i s , s p e c i f i e d , j o i n t s , b o l t s , n u t s , and
w a s h e r s s h a l l b e h o t - d i p bitumen c o a t e d .
3.9.6 C o r r o s i v e S o i l . Where s c h e d u l e d or o r d e r e d , steel o r cast i r o n f i t t i n g s and j o i n t s t h a t are t o b e
s u b j e c t e d t o c o r r o s i v e s o i l c o n d i t i o n s s h a l l b e t r e a t e d w i t h a c o m p a t i b l e primer, packed w i t h a
bitumen-based or t a r - b a s e d mastic, and wrapped w i t h an approved p l a s t i c s t a p e , or p r o t e c t e d w i t h c,tiit.r
s c h e d u l e d or approved materials.
3.10 VALVES. U n l e s s o t h e r w i s e s t a t e d i n t h e project s p e c i f i c a t i o n , v a l v e s s h a l l comply w i t h t h e requiremerlts

of SABS 1200 LK.
S A t E 1 2 0 0 L-19f1.3 B
Medium-prcssure pi.pe1 i n e s
3.11 MANHUI.I?S AtJD SURFACE DOXKS

3.11.1 B r i c k s . B r i c k s s h a l l b e o b t a i n e d from a n approved m a n u f a c t u r e r and s h a l l b e e i t h e r y e n c r a l p u r p o s e
( s p e c i a l ) , b u r n t c l a y , or e n g i n e e r i n g b r i c k s t h a t comply w i t h t h e a p p l i c a b l e r e q u i r e m e n t s o f S A R S 22'7. or
C l a s s S 1 4 c a l c i u m s i l i c a t e b r i c k s t h a t comply w i t h t h e a p p l i c a b l e r e q u i r e m e n t s o f S A R S 285.
The C o n t . r a c t o r s h a l l submit t o t h e E n g i n e e r s a m p l e s o f t h e b r i c k s t h a t h e i n t e n d s u s i n q i n t h e
c o n s t r u c t i o n o f t h e W o r k s (see S u b c l a u s e 3 . 1 o f SADS 1 2 0 0 A or SABS 1 2 0 0 A A , a s a p p l i c a b l e ) . The s a m p l r s
of b r i c k s t h a t a r e approved w i l l b e r e t a i n e d by t l i e E n g i n e e r .
3.11.2 P r e c a s t C y l i n d e r s . P r e c a s t c y l i n d e r s may b e o f spun c o n c r e t e , a s b e s t o s cement, g l a s s r e i n f o r c e d
p o l y e s t e r , or PVC, e x c e p t where p a r t i c u l a r materials are r e q u i r e d i n t e r m s o f t h e s c h e d u l e or t h e p r o . j e c t
specification. P r e c a s t c o n c r e t e c y l i n d e r s s h a l l comply w i t h t h e a p p l i c a b l e r e q u i r e m e n t s o f S A R S 1 2 9 4 .
S e c t i o n a l spun c o n c r e t e c y l i n d e r s s h a l l comply w i t h tlir reqriirnment:~ f o r p i p e s of SC L y p ~ ,C l a s s A , o f
SABS 677. J o i n t i n y between c y l i i i d e r s s h a l l b e o f t h e i n t e r l o c k i n g sel f - c e n t r i n g t y p e s u i t a b l e f o r
sealing.
3.1.1.3 C o n c r e t e . Except a s r e q u i r e d i n 3 . 1 1 . 2 , c o n c r e t e s h a l l comply w i t h t h e r e q u i r e m e n t s o f SABS 1 2 0 0 C; or
___.___
SABS 1 2 0 0 GA, a s a p p l i c a b l e .
3.11.4 S t e p I r o n s . Step i r o n s s h a l l b e o f malleable cast i r o n complying w i t h t h e a p p l i c n h l e r e q u i r e m e n t s of
RS 1247 and o f l e n g t h s u i t a b l e f o r f i x i n g i n b r i c k , i n - s i t u c o n c r e t e , or p r e c a s t c o n c r e t e , a s a . p.p l i c a h l ~ .
3.11.. 5 Manhole Covers and Frames
3.11.5.1 U n l e s s o t h e r w i s e r e q u i r e d i n terms o f t h e project s p e c i f i c a t i o n , c o v e r s and frames f o r manholes s h a l l
comply w i t h t h e r e q u i r e m e n t s o f SABS 5 5 8 f o r Type 2 6 i n t h e case o f manholes i n r o a d s and o t h e r areas
s u b j e c t t o road t r a f f i c l o a d s , and Type 4 i n t h e case o f manholes i n a r e a s n o t s u b j e c t t o s u c h l o a d s .
3.11.5.2 Covers and f r a m e s f o r manholes s h a l l b e s u p p l i e d i n matching sets. The c o v e r and frame o f e a c h set s h a l l
e a c h b e a r a serial number ( a p p l i e d by means of a n o i l p a i n t ) t o e n a b l e t h e s e t s t o b e i d e n t i f i e d .
The C o n t r a c t o r s h a l l e n s u r e t h a t , when i n s t a l l e d , t h e c o v e r s and f r a m e s s t i l l comply w i t h t h e
r e q u i r e m e n t s o f SARS 5 5 8 f o r freedom from warp and e v e n n e s s of s e a t i n g .
3.11.6 S u r f a c e Boxes-. S u r f a c e b o x e s may h e o f C I o r , p r o v i d e d t h a t t h e y conform to t h e r e l e v a n t s h a p e s and
i n t e r n a l d i m e n s j o n s g i v e n i n SABS 5 5 8 , o f materials t h a t comply w i t h t h e a p p l i c a b l e r e q u i r e m e n t s of
3.11.2. C a s t i r o n b o x e s s h a l l comply w i t h t h e r e q u i r e m e n t s of SABS 5 5 8 f o r Type 3A i n t h e case o f
s u r f a c e boxes f o r g a t e and s c o u r v a l v e s , and f o r Type 5 i n t h e case o f s u r f a c e b o x e s f o r h y d r a n t s arid a i r
v a l v e s . A l l C I s u r f a c e b o x e s s h a l l h a v e been h o t d i p p e d i n a n a c c e p t a b l e b i t u m i n o u s compound b e f o r e
d e s p a t c h from t h e m a n u f a c t u r e r ' s w o r k s .
4. PLANT
4.1 HANDLING AND R I G G I N G . The p l a n t and r i g g i n g equipment used by t h e C o n t r a c t o r f o r t h e h a n d l i n g and
p l a c i n g o f p i p e s s h a l l b e s u c h t h a t . no p i p e s h e l l i s o v e r - s t r e s s e d d u r i n g any o p e r a t i o n c o v e r e d by t h e
specification.
4.2 SETTING OUT. The C o n t r a c t o r may u s e a n y a c c e p t a b l e d e v i c e , i n c l u d i n g o n e i n c o r p o r a t i n g a laser beam, t o

c o n t r o l t h e a l i g n m e n t and l a y i n g o f t h e p i p e l i n e .
4.3 TESTING. The C o n t r a c t o r s h a l l p r o v i d e a l l t h e equipment, m a t e r i a l s , t o o l s , and f i t t i n g s r e q u i r e d f o r t h e

performance o f t h e tests g i v e n i n C l a u s e 7.
5. CONSTRUCTION
5.1 LAYING
5.1.1 G e n e r a l . A p i p e l i n e s h a l l b e l a i d and hedded (see SABS 1 2 0 0 LR) t o even g r a d e s and t o t h e l e v e l s atid
a l i g n m e n t s shown on t h e d r a w i n g s or as d i r e c t e d . I t s h a l l be l a i d c e n t r a l l y i n t h e t r e n c h i n s u c h a
manner t h a t t h e s i d e a l l o w a n c e conforms t o t h e a p p l i c a b l e v a l u e s p e c i f i e d i n C l a u s e R of SARS 1 2 0 0 DB.
For ease of i n s p e c t i o n and t e s t i n g t h e p i p e s s h a l l b e l a i d w i t h t h e m a n u f a c t u r e r ' s class and q u a l i t y
i d e n t i f i c a t i o n m a r k s v i s i b l e from t h e t o p o f t h e t r e n c h , u n l e s s , i n t h e c a s e of l a r g e p i p e s , t h e p o s i t i o n
of l i f t i n g e y e s r e n d e r s t h i s i m p r a c t i c a b l e .
C o n t r o l o f l a y i n g and b e d d i n g s h a l l b e by means o f b o n i n g r o d s and s i g h t r a i l s or a n a c c e p t a b l e l a s e r
beam d e v i c e . S i g h t r a i l s s h a l l b e p a i n t e d b l a c k and w h i t e and s h a l l b e f i x e d s e c u r e l y and a c c u r a t e l y .
5.1.2 Damage. Each p i p e and each f i t t i n g s h a l l b e t h o r o u g h l y c l e a n e d and c a r e f u l l y examined f o r damage and
d e f e c t s immediately b e f o r e l a y i n g . Should any damaged or d e f e c t i v e p i p e or f i t t i n g b e l a i d , i t s h a l l b e
removed and r e p l a c e d a t t h e C o n t r a c t o r ' s e x p e n s e and t o t h e s a t i s f a c t i o n o f t h e E n g i n e e r .
5.1.3 ___-
Keepiny P i p e l i n e s Clean. Every r e a s o n a b l e p r e c a u t i o n s h a l l h e t a k e n t o p r e v e n t t h e e n t r y o f f o r e i . q n
m a t t e r and water i n t o t h e p i p e ( s ) . A t t h e close of e a c h d a y ' s w o r k or a t any time when w o r k i s suspended
f o r a s i g n i f i c a n t p e r i o d , t h e l a s t l a i d s e c t i o n o f each p i p e s h a l l b e p l u g g e d , c a p p e d , or o t h e r w i s e
t i g h t l y c l o s e d u n t i l l a y i n g i s recommenced.
During l a y i n g and j o i n t i n g o f p i p e s and u n t i l t h e p i p e l i n e ( s 1 h a s / h a v e p a s s e d t h e r e q u i r e d a c c e p t a n c e
t e s t s and t h e t r e n c h e s have been b a c k f i l l e d , a l l t r e n c h e s s h a l l b e k e p t i n a s t a t e which, i n t h e o p i n i o n
o f t h e E n g i n e e r , is r e a s o n a b l y d r y .
5.1.4 Depths and Cover
5.1.4.1 U n l e s s o t h e r w i s e shown on t h e d r a w i n g s or r e q u i r e d i n terms o f t h e p r o j e c t s p e c i f i c a t i o n , or o r d e r e d , t h e
d e p t h of e x c a v a t i o i i f o r t r e n c h e s f o r medium-pressure p i p e l i n e s s h a l l n o t e x c e e d 1.5 m.
5.1.4.2 P i p e s s h a l l b e l a i d t o even g r a d e s w i t h t h e s p e c i f i e d c o v e r . Where so r e q u i r e d , t h e c o v e r may b e
i n c r e a s e d g r a d u a l l y by d e f l e c t i o n a t p i p e j o i n t s , b u t t h e d e f l e c t i o n s h a l l n o t b e g r e a t e r (and s h o u l d
g e n e r a l l y b e less) t h a n t h e d e f l e c t i o n recommended by t h e m a n u f a c t u r e r o f t h e p i p e ( e . g . t h e d e f l e c t i o n
s h a l l n o t exceed 1 , s p e r j o i n t i n t h e case o f AC p i p e s ) .
9 SARS 1 2 0 0 1 ~ 1 9 8 3
Medium-isressure p i p e l i n e s
5.1.4.3 Tlie minimnm c l e a r a n c e bctwcwn t h e o u t s i d e of a p i p e l i n e h e i n q l a i d and t h e o u t - s i d e of any o t h c r 4 > 1 i v L l i a t

it crosses s h a l l b e 1 5 0 nim. Where t h i s r e q u i r e m e n t c o n f l i c t s w i t h t h e r e q u i r e m e n t s f o r c o v e r o v e r t h e
p i p e l i n e t h e C o n t r a c t o r s h a l l a s k t h e E n g i n e e r f o r w r i t t e n i n s t r u c t i o n s and s h a l l c a r r y o u t t h e w o r k i n
accordance with t h o s e i n s t r u c t i o n s .
5.1.4.4 Unless o t h e r w i s e s p e c i f i e d i n t h e p r o j e c t s p e c i f i c a t i o n , a p i p e l i n e feeding a f i r e hydrant s h a l l be l a i d
a t a l e v e l t h a t e n s u r e s t h a t t h e t o p o f t h e t h r e a d e d o u t l e t is n o t more t h a n 400 mm below t h e l e v e l a t
which t h e t o p of t h e h y d r a n t c o v e r is CO b e set.
5.1.4.5 A d o u b l e - f l a n g e d d i s t a n c e p i e c e s h a l l b e u s e d when n e c e s s a r y t o e n s u r e compliance w i t h 5.1.4.4 (see
Drawings 1.-2 and L-3) or w i t h any d e p t h r e q u i r e m e n t g i v e n on t h e d r a w i n g s f o r a n a i r v a l v e .
5.2 JOINTLNG METllODS

5.2.1 D e t a c h a b l e C o u p l i n g s (AC and UPVC P i p e l i n e s ) . . Each e n d o f AC and uPVC p i p e s s h a l l b e t h o r o u g h l y c l e a n e d
by b r u s h i n g and w i p i n g immediately b e f o r e b e i n g j o i n t e d . A l l r u b b e r r i n g s and s e a l s s h a l l b e c a r e f u l l y
i n s p e c t e d a f t e r b e i n g p l a c e d i n p o s i t i o n and b e f o r e t h e j o i n t is c l o s e d , t o e n s u r e t h a t t h e y h a v e n o t
s u f f e r e d a n y c u t s , tears, or o t h e r damage, and are n o t i n any o t h e r way d e f e c t i v e . Only t h e l u b r i c a n t
recommended by t h e m a n u f a c t u r e r s h a l l b e u s e d f o r s l e e v e - t y p e c o u p l i n g s and r u b b e r i n s e r t i o n r i n g s o f AC
pipes. P o l y u r e t h a n e j o i n t s f o r uPVC p i p e s s h a l l b e l u b r i c a t e d w i t h s o f t s o a p or s i m i l a r material
approved by t h e m a n u f a c t u r e r . Grease d e r i v e d f r o m p e t r o l e u m p r o d u c t s s h a l l n o t b e u s e d i n uPVC p i p e
joints. A UPVC p i p e l i n e s h a l l be j o i n t e d i n a c c o r d a n c e w i t h t h e m a n u f a c t u r e r ' s i n s t r u c t i o n s .
An AC p i p e l i n e s h a l l b e j o i n t e d i n a c c o r d a n c e w i t h t h e m a n u f a c t u r e r ' s i n s t r u c t i o n s . I n p a r t i c u l a r ,
j o i n t s i n s u c h p i p e l i n e s w i t h C I d e t a c h a b l e c o u p l i n g s s h a l l have a g a p , a f t e r l a y i n g and j o i n t i n g , o f
a p p r o x i m a t e l y 1 0 mm between t h e e n d s o f t h e p i p e s and c e n t r a l t o t h e collar, to allow f o r e x p a n s i o n when
t h e p i p e s are f i l l e d and h a v e a b s o r b e d moisture.
5.2.2 Flanges (Steel Pipelines). I n t h e j o i n t i n g o f steel p i p e s w i t h f l a n g e s , s p e c i a l care s h a l l h e t a k e n t o
a l i g n , g r a d e , and l e v e l t h e p i p e s , s p e c i a l s , and v a l v e s t o a v o i d s t r a i n i n g o f t h e f l a n g e s . A l l bitumen
and p a i n t s h a l l h e removed from t h e m a t i n g f a c e o f e a c h f l a n g e i m m e d i a t e l y b e f o r e j o i n t i n y . Insertion
p i e c e s t h a t comply w i t h t h e a p p l i c a b l e r e q u i r e m e n t s o f 3 . 8 . 3 and t h a t have a c c u r a t e l y c u t h o l e s f o r b o l t s
s h a l l b e p l a c e d t o form a c o n t i n u o u s o n e - p i e c e r i n g between t h e f l a n g e s . B o l t s s h a l l b e t i g h t e n e d up
e v e n l y i n o p p o s i t e p a i r s to e n s u r e u n i f o r m b e a r i n g on t h e i n s e r t i o n . Care s h a l l b e t a k e n t o a v o i d damage
t o t h e i n t e r n a l s u r f a c e o f t h e p i p e s d u r i n g assembly o f t h e p i p e l i n e .
Wherever loose f l a n g e s are welded o n t o p i p e l i n e s , t h e C o n t r a c t o r s h a l l e n s u r e t h a t t h e i n n e r l i n i n g i s
r e s t o r e d t o t h e t h i c k n e s s s p e c i f i e d f o r s u c h l i n i n g and t h a t t h e new l i n i n g is s o u n d l y j o i n t e d t o t h e
existing lining.
5.2.3 Welding ( S t e e l P i p e l i n e s o f Diameter 600 mm o r g r e a t e r ) . F i e l d w e l d i n g o f steel p i p e l i n e s o f d i a m e t e r
-
600 mm or g r e a t e r s h a l l comply w i t h t h e r e l e v a n t r e q u i r e m e n t s o f API 1104 and s h a l l b e c a r r i e d o u t by
w e l d e r s who are competent i n terms o f t h e p r o c e d u r e a p p r o v a l test g i v e n i n API 1104. P i p e l i n e s o f
d i a m e t e r less t h a n 600 mm s h a l l n o t b e welded i n t h e f i e l d .
The p i p e t r e n c h f o r welded steel p i p e l i n e s may b e b a c k f i l l e d a f t e r , when r e l e v a n t , c o m p l e t i o n of
r a d i o g r a p h i c e x a m i n a t i o n (see 7.2.1 and 7.2.2).
5.2.4 C o n c r e t e S p i g o t and S o c k e t P i p e l i n e s . Where r u b b e r j o i n t s e a l i n g g a s k e t s a r e u s e d i n f l e x i b l e j o i n t s of
a c o n c r e t e s p i g o t and s o c k e t p i p e l i n e , t h e g a s k e t s s h a l l b e i n s t a l l e d f r e e from l o o p s and t w i s t s and
s h a l l be e v e n l y compressed around t h e j o i n t p e r i m e t e r . The g a s k e t s s h a l l b e p l a c e d i n t h e i r d e s i g n e d
p o s i t i o n and t h e C o n t r a c t o r s h a l l u s e f e e l e r g a u g e s i n s e r t e d i n t o t h e s o c k e t t o check t h e p o s i t i o n i n g o f
t h e g a s k e t a f t e r completion of each j o i n t .
S u b j e c t t o t h e p r o v i s i o n of a g a p between p i p e e n d s as recommended by t h e p i p e m a n u f a c t u r e r , p i p e s s h a l l
b e pushed f u l l y home a t j o i n t s . P a r t i c u l a r a t t e n t i o n s h a l l b e p a i d t o o b t a i n i n g a smooth c o n t i n u o u s b o r e
t h r o u g h o u t t h e p i p e l i n e , w i t h o u t s t e p s between a d j a c e n t p i p e s .
5.3 SETTING OF VALVES, SPECIALS, AND FITTINGS. f l n l e s s o t h e r w i s e s p e c i f i e d or d i r e c t e d , g a t e v a l v e s s h a l l b e

s e t u p r i g h t and b u t t e r f l y v a l v e s s h a l l b e set w i t h t h e main s h a f t s h o r i z o n t a l . A l l v a l v e s , s p e c i a l s , and
f i t t i n g s s h a l l b e c o r r e c t l y s e t , s u p p o r t e d , and p l a c e d i n p o s i t i o n a s t h e work p r o c e e d s , and s h a l l b e
properly jointed to t h e i r respective pipes.
I n u r b a n , i n d u s t r i a l , and similar a r e a s v a l v e s , s p e c i a l s , and f i t t i n g s s h a l l b e l o c a t e d i n t h e p o s i t i o n s
shown on t h e d r a w i n g s or as o t h e r w i s e d i r e c t e d (and n o t m e r e l y t o s u i t s t a n d a r d l e n g t h s of p i p e ) b u t i n
open c o u n t r y areas t h e y may b e l o c a t e d t o s u i t t h e p i p e l e n g t h s . ( S e e also C l a u s e 6.)
A f t e r c u t t i n g a n AC p i p e t o s u i t t h e p o s i t i o n o f a v a l v e , s p e c i a l , or f i t t i n g , t h e C o n t r a c t o r s h a l l , by
means o f a n approved f i e l d - t u r n i n g machine, t u r n t h e c u t e n d s t o s u i t t h e c o u p l i n g s l e e v e . F i l i n g o f t h e
e n d s o f a n AC p i p e w i l l n o t b e p e r m i t t e d .
5.4 CONCRETE CASING. Where t h e E n g i n e e r r e q u i r e s p i p e s t o be e n c a s e d , a s t r e n g t h 1 5 MPa/37,5 mm, or s u c h

o t h e r s t r e n g t h a s i s s c h e d u l e d . s h a l l be used. N o part o f t h e c o n c r e t e c a s i n g s h a l l h e closer t h a n
150 mm t o any f l e x i b l e j o i n t of a c o n c r e t e - e n c a s e d pipeline.
The p i p e t r e n c h f o r a c o n c r e t e - e n c a s e d p i p e l i n e s h a l l b e e x c a v a t e d t o t h e d e p t h below t h e bottom s u r f a c e
o f t h e p i p e , as o r i l e r e d or shown on t h e d r a w i n g s , and to s u f f i c i e n t w i d t h t o allow f o r t h e c o n c r e t e t o be
p l a c e d t o t h e f u l l s p e c i f i e d w i d t h . The bottom of t h e t r e n c h s h a l l b e trimmed t r u e t o l i n e and q r a d e . A
l i g h t c o n c r e t e s c r e e d s h a l l b e p l a c e d o n t h e bottom o f t h e t r e n c h , concrete s a d d l e s or p a d s o f t h e
r e q u i s i t e t h i c k n e s s s p a c e d s u i t a b l y , and t h e p i p e l i . n e l a i d on them t r u e t o l i n e and g r a d e . After being
j o i n t e d t h e p i p e s s h a l l b e t e s t e d i n a c c o r d a n c e w i t h t h e a p p l i c a b l e tests g i v e n i n C l a u s e 7, care b e i n g
t a k e n t o e n s u r e t h a t t h e p i p e s d o n o t move d u r i n g t e s t i n g . A f t e r t h e p i p e l i n e h a s been t e s t e d , s u i t a b l e
f o r m w o r k s h a l l b e e r e c t e d and c o n c r e t e c a r e f u l l y p l a c e d and v i b r a t e d i n p o s i t i o n u n d e r n e a t h t h e p i p e and
up b o t h s i d e s . The c o n c r e t e l e v e l s h a l l b e r a i s e d e q u a l l y on b o t h s i d e s o f t h e p i p e u n t i l encasement i s
c o m p l e t e and a c o v e r o v e r t h e s u r f a c e o f t h e p i p e i s p r o v i d e d t h a t i s nowhere less t h a n t h a t o r d e r e d or
shown on t h e drawings. N o e a r t h f i l l i n q over t h e c o n c r e t e s h a l l b e commenced u n t i l a t l e a s t 7 d a f t e r
t h e c o n c r e t e h a s been p l a c e d or u n t i l t h e c o n c r e t e h a s a t t a i n e d a s t r e n g t h of a t l e a s t 1 0 MPa.
SABS 1200 L-1983 10
5.5 ANCHOH/TIIRUST 131,OCKS AND PEDESTAIS. A t tees, b e n d s , termirial v a l v e s , e n d c a p s , arid where t , t h e r w i s e

d i r e c t e d , a n c h o r / t h r u s t b l o c k s s h a l l be c o n s t r u c t e d t o d i m e n s i o n s o r d e r e d or shown on t h e d r a w i n g s .
U n l e s s o t h e r w i s e s p e c i f i e d , a n c h o r / t h r u s t b l o c k s and p e d e s t a l s s h a l l b e c o n s t r u c t e d o f s t r e n g t h
15 MPa/37,5 m m coricrcte or s u c h o t h e r s t r e n g t h a s is s c h e d u l e d .
The c o n c r e t e s h a l l h e w e l l punned round t h e p i p e arid, i f i n t r e n c h e s , a g a i n s t t h e u n d i s t u r b e d f a c e s and
bottom o f t h e t r e n c h . H a c k f i l l i n g b e h i n d or u n d e r t h r u s t f a c e s w i l l n o t b e p e r m i t t e d . Excess excavation
s h a l l b e r e p l a c e d w i t h t h e p r e s c r i b e d mix c o n c r e t e g i v e n a b o v e f o r a n c h o r / t h r u s t b l o c k s a t t h e
C o n t r a c t o r ' s e x p e n s e u n l e s s a n i t e m is s c h e d u l e d t o c o v e r payment f o r o v e r b r e a k . C a r e s h a l l b e t a k e n t o
l e a v e tile j o i n t s a c c e s s i b l e . N o a n c h o r / t h r u s t b l o c k s and p e d e s t a l s shall b e concreted u n t i l l.he a p p r o v a l
o f t h e Engi.neer h a s been o b t a i n e d .
5.6 VALVE AND HYDI<ANT C1lAMHE;RS

5.6.1 ---
General. On r e t i c u l a t i o n p i p e l i n e s o f nominal d i a m e t e r 200 mm o r less, e a c h v a l v e s h a l l be housed i n a
chamber a s d e t a i l e d on Drawing 1,-1. On p i p e l i n e s o f nominal d i a m e t e r u p to and i n c l u d i n g 275 mm, u n l e s s
o t h e r w i s e shown on t h e d r a w i n g s or s c h e d u l e d as manholes, chambers s h a l l b e c o n s t r u c t e d a r o u n d a l l g a t e
and s c o u r v a l v e s , h y d r a n t s , and a i r v a l v e s a s s p e c i f i e d i n 5.6.2.
5.6.2 C o n s t r u c t i o n o f Chambers. A f t e r a l l items have b e e n t e s t e d i n a c c o r d a n c e w i t h t h e a p p l i c a b l e o f t h e
tests g i v e n i n C l a u s e 7 and found a c c e p t a b l e , e x c a v a t i o n s s h a l l b e b a c k f i l l e d t o t h e l e v e l o f t h e t o p o f
t h e p i p e w i t h material s e l e c t e d and compacted a s s p e c i f i e d i n SABS 1200 LB. From t h i s l e v e l b r i c k w o r k or
p r e c a s t u n i t s , as approved, f o r e a c h chamber as d e t a i l e d on Drawings L - 1 , L-2, and L - 3 , and as s p e c i f i e d
i n 5.8, s h a l l b e c o n s t r u c t e d t o a h e i g h t s u c h t h a t t h e t o p of t h e v a l v e o r h y d r a n t s u r f a c e box i s a t t h e
l e v e l o f t h e s i d e w a l k or street, or a t a h e i g h t 5 0 nun above ground l e v e l i n t h e c a s e o f u n s u r f a c e d areas.
The uppcr d i m e n s i o n s of t h e s t r u c t u r e s h a l l b e s u c h a s t o f i t t h e b a s e o f t h e box. The s u r f a c e box s h a l l
b e y r o u t e d t o t h e t o p of t h e s t r u c t u r e and t h e n t h e e x c a v a t i o n s h a l l b e b a c k f i l l e d around t h e s t r u c t u r e
and t h e s u r f a c e box. The b a c k f i l l s h a l l b e w e l l compacted t o t h e l e v e l of t h e t o p o f t.he box, which
s h a l l b e h e l d f i r m l y i n p o s i t i o n by t h e f i l l .
5. 7 MANHOI,ES
5.7.1 G-
-eneral. Each v a l v e o f d i a m e t e r 300 mm and more s h a l l b e housed i n a manhole c o n s t r u c t e d i n a c c o r d a n c e
w i t h t h e d e t a i l s shown on t h e a p p l i c a b l e d r a w i n g s , and i n a c c o r d a n c e w i t h 5.8 or as o t h e r w i s e s p e c i f i e d
i n the project specification.
5.7.2 P r e c a s t Manholes. P r e c a s t manholes s h a l l b e c o n s t r u c t e d i n a c c o r d a n c e w i t h t h e a p p l i c a b l e d e t a i l s shown
on t h e drawings.
5.8 BRICKWORK IN CHAMBERS AND MANHOLES. Each chamber and manhole s h a l l b e b u i l t t o t h e d e t a i l s shown on a
p a r t i c u l a r drawiriq or a s shown on t h e a p p l i c a b l e t y p e drawing. The w a l l s s h a l l b e c o n s t r u c t e d i n a n
approved bond c o m p r i s i n g h e a d e r and s t r e t c h e r c o u r s e s w i t h t h e f a i r face on t h e i n s i d e . N o f a l s e headers
s h a l l b e b u i l t i n and o n l y whole b r i c k s s h a l l b e u s e d e x c e p t where c l o s u r e s are r e q u i r e d t o form bond.
The b r i c k s s h a l l b e w e l l soaked i n water i m m e d i a t e l y ' b e f o r e h e i n g l a i d and t h e c o u r s e o f b r i c k s last. l a i d
s h a l l b e w e l l w e t t e d b e f o r e f r e s h b r i c k s are l a i d upon i t . A l l walls s h a l l b e c a r r i e d u p r e g u l a r l y so
t h a t no p a r t of t h e w a l l i n g is more t h a n 1.3 m h i g h e r t h a n a n y a d j o i n i n g w a l l .
J o i n t s s h a l l b e f l u s h e d up s o l i d a t e v e r y c o u r s e t h r o u g h o u t t h e whole w i d t h o f e a c h c o u r s e , which s h a l l
b e l a i d on a s o l i d bed o f mortar o f t h i c k n e s s n o t e x c e e d i n g 1 0 mm, arid, when a p p l i c a b l e , t h e j o i n t s s h a l l
b e r a k e d o u t a s t h e work p r o c e e d s t o form a key f o r p l a s t e r .
Mortar f o r brickwork and p l a s t e r w o r k s h a l l b e composed of one p a r t o f cement t o t h r e e p a r t s of s a n d .
Sand s h a l l b e c l e a n p i t s a n d f r e e trom c l a y and o t h e r i m p u r i t i e s and, i f so d i r e c t e d , s h a l l b e p r o p e r l y
s c r e e n e d and washed.
I f r e q u i r e d , s t e p i r o n s f o r a manhole s h a l l b e b u i l t i n t o t h e s t r a i g h t o f t h e w a l l a t 300 mm i n t e r v a l s
s t a g g e r e d r i g h t and l e f t i n v e r t i c a l r o w s . C I f i t t i n g s s h a l l be bitumen p a i n t e d . Each C I c o v e r and
frame s h a l l b e g r o u t e d s o l i d l y o n t o t l i e s h a f t . C o n c r e t e s u r r o u n d s o f e a c h manhole s h a l l be f i n i s h e d o f f
t o suil: surrounding surfaces.
5.9 LIFT'ING AND RELAYlNG OF EXISTING PIPES. Where shown on t h e d r a w i n g s and where s c h e d u l e d , e x i s t i n g p i p e s
and f i t t i n g s t h a t are t o b e removed s h a l l b e l i f t e d and t h e materials r e c o v e r e d a s f a r as i s p r a c t i c a b l e .
The p i p e s and c o u p l i n g s s h a l l b e removed from t h e t r e n c h and p l a c e d i n t h e C o n t r a c t o r ' s s i t e store where
t h e y s h a l l b e c l e a n e d , s o r t e d , and l i s t e d . A copy o f t h e l i s t of undamaged material r e c o v e r e d s h a l l b e
handed t o t h e E n g i n e e r .
To a v o i d damaging tlie p i p e s , t h e C o n t r a c t o r s h a l l e x e r c i s e p a r t i c u l a r care i n e x c a v a t i n q AC p i p e l i n e s .
U n l e s s , i n t e r m s of t h e c o n t r a c t , o t h e r p i p e s are t o b e l a i d i n t h e same t r e n c h , e a c h t r e n c h s h a l l b e
b a c k f i l l e d as s p e c i f i e d i n SABS 1200 DB.
Where r e c o v e r e d p i p e s are s c h e d u l e d t o b e r e l a i d , r u b b e r r i n g s , i n s e r t i o n p a c k i n g s . damaged j o i n t s , and
rusted b o l t s s h a l l be replaced.
B e f o r e t h e y are r e l a i d , a n a c c e p t a b l e number o f t h e p i p e s s h a l l b e t e s t e d f o r compliance w i t h t h e
r e q u i r e m e n t s of t h e a p p l i c a b l e s p e c i f i c a t i o n f o r r e s i s t a n c e t o h y d r a i i l i c p r e s s u r e .
5.10 DISINFECTION OF PO'I'AHLB WATER PIPELINES. On c o m p l e t i o n of t h e l a y i n g and t e s t i n g , e a c h p o t a b l e water

p i p e l i n e s h a l l b e d i s i n f e c t e d as f o l l o w s :
a ) The p i p e l i n e s h a l l b e f l u s h e d o u t w i t h c l e a n w a t e r u n t i l a l l s e d i m e n t and o t h e r f o r e i g n matter have
been removed.
b ) The p i p e l i n e s h a l l t h e n b e f i l l e d w i t h water c o n t a i n i n g 0,15 g/e o f c a l c i u m h y p o c h l o r i t e . The
s o l u t i o n s h a l l b e a l l o w e d to flow s l o w l y i n t o t h e p i p e l i n e u n t i l it f i l l s t h e whole p i p e l i n e and s h a l l b e
l e f t t h e r e f o r a t l e a s t 24 h .
c) The p i p e l i n e s h a l l t h e n b e t h o r o u g h l y and r e p e a t e d l y f l u s h e d w i t h c l e a n w a t e r u n t i l a sample o f t h e
wasbwater drawn f r o m t h e p i p e l i n e c o m p l i e s w i t h t h e r e q u i r e m e n t s f o r p o t a b l e water of t h e local a u t h o r i t y
or o f t h e a u t h o r i t y s u p p l y i n g s u c h water t o t h e area.
11 S A W 1200 L-1983
Medium-pressure pipe1 ines
6. TOLERANCES
6.1 GENERAL. No deviation will be permitted from the minimum cover specified or shown on the drawings.
6.2 CONTROL POINTS. For the purposes of Lhis clause valves set on the centre line of the pipeline and
designated changes in gradient shall be regarded as control points and shall be located with a
permissible vertical deviation of 2 100 mm on the centre line. The same deviation will be permissible
laterally except where the Contractor is required to lay the pipeline at a designated distance from a
fence line, kerb line, or boundary, in wtiich case thp permissible deviation shall be 20 mm.
Unless otherwise directed and subject to a permissible deviation (measured along the centre line) of
-+ 4 m, scour valves shall be located at the lowest pints in pipelines and air valves at the highest
points.
6.3 ALIGNMENT (PLAN AND LEVEL). Unless otherwise directed, the permissible deviation in alignment between
control points (see 6.2) from a straight line joining the control points, when measured on thp top centre
of the pipeline, shall be + 100 mm or 5 20 4: of the nominal diameter of the pipe, whichever 1s the
larger, and the permissible deviation per pipe length shall be 2 20 mm.
The permissible deviation from the designated level at any point on the invert of the pipeline shall be
-+ 50 mm or 1 1 0 4: of the nominal diameter of the pipe, whichever is the larger.
6.4 MANHOLES, VhLVE CBAMBERS, ETC. Manholes, valve chambers, and the like shall be constructed Centrally on
the control points and, with the exception of tolerances that affect access to bolts, nuts, etc., with a
permissible deviation of 2 50 mm 011 a l l clearance dimensions. The clearance dimension between the
outside of each nut and bolt-head and the inside face of the wall of a structure or any other fitting
shall be at least the specified value.
7. TESTING
7.1 GENERAL. AS the work proceeds, pipelines shall be tested in convenient lengths by means of test
equipment supplied by the Contractor (see 4.3).
In the case of steel pipelines butt-welded in the field, joints shall be tested in accordance with 7.2
immediately after being made.
Each test shall be carried out in the presence of the Engineer or his representative. The Contractor
shall be responsible for carrying out all tests and for all expenses incurred in this connection (see
8.2). When carrying out the hydraulic test (see 7-31, the Contractor shall ensure that all valves, tees,
and bends are properly secured and shored to prevent movement of pipes and fittings and, should any such
movement occur, the Contractor shall, at his own expense, reposition and, if necessary, repair the pipes
and fittings and the securing means.
Until each section of the pipeline has been subjected to the hydraulic test and has complied with the
applicable requirement for leakage rate given in 7.3.3, the pipeline will not be accepted. The hydraulic
test shall be repeated until the Engineer is satisfied that the section under test complies with the said
requirement.
7.2 INITIAL TESTS ON WELDED STEEL PIPES

7.2.1 Dye-Penetrant Test. Except where they are subject to radiographic testing, the inside and outside of
every weld in steel specials and, where so ordered, in pipes, shall be subjected to a dye-penetrant test
carried ouC as specified in RS 4416 and (a)-(g) below:
a) The Contractor shall obtain the approval of the Engineer for the group of dye-penetrant and developer
that he proposes to use for the test.
b) The test shall be applied to shop welding before despatch of specials or pipes to the Site. AS pipe
laying progresses, field welds shall be subjected to the test soon after each weld is completed.
c) In order to obtain a surface that is dry, clean, and free from scale, dirt, and grease, the Contractor
may grind but he shall not grit blast the surface.
d) The temperature of the surface to which the developer and the penetrant are applied shall not be below
16 OC or above 52 "C.
e ) Observations for indications shall be made not less than 15 min and not more than 60 min after the
application of the penetrant.
f) Any surfaces on which non-relevant indications are observed shall be explored by visual methods and,
if considered necessary by the Engineer, such surfaces shall be cleaned and retested.
4 ) Welds that show no relevant trace of dve on the develo~erwill be acceDted.
7.2.2 Radiographic Examination. Welded joints shall be examined radiographically as and to the extent set out
in the project specification (see 5.2.3).
7.3 STANDARD HYDRAULTC PIPE TEST

7.3.1 Test Pressure and Time of Test
7.3.1.1 Unless otherwise ordered, hydraulic testing shall be commenced only after permanent anchor blocks have
attained their specified strength, i.e. after 28 d.
After tlie pipe trench has been partially backfilled and before ,the trench is filled in at the pipe joints
and the fittings, the pipeline shall be tested in sections between isolating valves and/or end caps,
blank flanqes, or other isolating devices, at the pressure given in 7.3.1.2 appropriate to the type and,
when relevant, class of pipe in the pipeline under test. Where mixed types or classes of pipe occur, and
where the pipeline traverses a wide range of altitudes, the Engineer may require that temporary valves or
blank flanges be inserted and that the pipeline be tested in reduced lengths and, in addition, at the
point of maximum pressure (see 8.2.10).
7.3.1.2 Subject to the provisions of 7.3.1.3 and 7.3.1.4, the test pressure for field testing shall be 1.25 (or
such other factor as is stated in the project specification) times the maximum working pressure laid down
in the project specification.
7.3.1.3 The test pressure applied over any section of pipeline under test, taking any differences in elevation
along the pipeline into account, shall be such that the pressure at any point along the section is not
less than the design pressure or more than 1,5 times the design maximum working pressure at these points.
SARS 1200 L-1983 12

7.3.1.4 The f i e l d t e s t p r e s s u r e shall n o t e x c e e d t h e a p p r o p r i a t e of t h e f o l l o w i n g v a l u e s :

Type o f p i p e ___
Specification T._
- e sIt p r e s s u r e e x p r e s s e d as a - p e r c e n t a g e
number of t h e s p e c i f i e d h y d r a u l i c t e s t p r e s c
A s b e s t o s cement (COD) 6-S ) 75 % o f t h e t e s t p r e s s u r e f o r p e r m e a b i l i t y
(CID) SABS 946) test
Mild S t e e l SABS 719 50 % (3,s MPa max.)
Reinforced c o n c r e te SABS 676 75 %
Prestressed concrete SARS 975 75 % of p r e s s u r e s t a t e d i n t h e p r o j e c t s p e c i f i c a t i o n
Flanqed c a s t i r o n RS 2035 67 % (of w o r k s t e s t p r e s s u r e )
Black p o l y e t h y l e n e SARS 533 100 %
UPVC SABS 966 75 %
7.3.1.5 Where c i r c u m s t a n c e s p e r m i t . i n t h e case of asbestos cement and c o n c r e t e p i p e s , e a c h s e c t i o n s h a l l be
f i l l e d w i t h w a t e r 24 h b e f o r e t h e t e s t p r e s s u r e is a p p l i e d t o e n s u r e s a t u r a t i o n o f t h e p j , p e l i n e .
Care s h a l l b e t a k e n t o e n s u r e t h a t a l l a i r i s e x p e l l e d from t h e l i n e t o be t e s t e d a f t e r it h a s b e e n
f i l l e d and b e f o r e t h e t e s t commences.
1.3.2 V i s i b l e Leaks
7.3.2.1 Except a s a l l o w e d i n 7.3.2.2, t h e s p e c i f i e d t e s t p r e s s u r e s h a l l b e m a i n t a i n e d f o r a p e r i o d of a t l e a s t
3 h (or such l o n g e r p e r i o d a s i s n e c e s s a r y for i n s p e c t i o n o f t h e p i p e l i n e ) by means o f a s u i t a b l e pump,
d u r i n g which p e r i o d a l l p i p e s , s p e c i a l s , j o i n t s , and f i t t i n g s s h a l l b e c a r e f u l l y i n s p e c t e d f o r l e a k s .
A l l v i s i b l e l e a k s s h a l l b e made good a n d a n y p i p e , s p e c i a l , or f i t t i n g f o u n d t o b e d e f e c t i v e s h a l l b e
removed and r e p l a c e d a t t h e e x p e n s e o f t h e C o n t r a c t o r and s u c h r e p l a c e m e n t material s h a l l , a f t e r
i n s t a l l a t i o n , b e t e s t e d a t t h e expense o f t h e Contractor.
7.3.2.2 l n t h e case of p i p e s of nominal d i a m e t e r u n d e r 400 mm, t h e t e s t p e r i o d may be r e d u c e d p r o p o r t i u n a l l y t o
t h e nominal d i a m e t e r o f t h e p i p e , p r o v i d e d t h a t i n no case s h a l l t h e test p e r i o d b e less t h a n 1 h.
1.3.3 P e r m i s s i b l e Leakage Rates. The test p r e s s u r e s h a l l b e m a i n t a i n e d for a f u r t h e r p e r i o d o f 1 h a f t e r t h e
c o m p l e t i o n of t h e t e s t p e r i o d g i v e n i n 7.3.2, d u r i n g which t i m e t h e volume of water r e q u i r e d t o b e pumped
i n t o t h e p i p e l i n e f o r m a i n t e n a n c e o f t h e p r e s s u r e s h a l l b e measured. N o a d d i t i o n a l water s h a l l b e
r e q u i r e d i n t h e c a s e o f c o n t i n u o u s l y welded steel p i p e s , and i n o t h e r cases t h e volume s h a l l n o t e x c e e d
t h e v a l u e , i n l i t r e s , c a l c u l a t e d from t h e a p p l i c a b l e o f t h e f o l l o w i n g f o r m u l a e :
a) A s b e s t o s cement and c o n c r e t e p i p e s and c o n c r e t e - l i n e d steel p i p e s :
0,075 x d i a m e t e r o f p i p e i n m i l l i m e t r e s
x length of test s e c t i o n i n kilometres
x s q u a r e root o f t h e t e s t p r e s s u r e i n m e g a p a s c a l s
b ) J o i n t e d p i p e s i n steel, c a s t i r o n , b l a c k p o l y t h e n e , and uPVC:
0.01 x d i a m e t e r o f p i p e i n millimetres
x length o f test s e c t i o n i n kilometres
x s q u a r e root o f t h e t e s t p r e s s u r e i n megapascals
7.4 TESTS ON EPOXY COATINGS. The C o n t r a c t o r s h a l l c a r r y 'out t h e f o l l o w i n g tests on epoxy c o a t i n g s o n steel

pipes:
a) T e s t s f o r p i n h o l e s and h o l i d a y s . A low-voltage p i u h o l e d e t e c t o r h a v i n g a w e t sponge p r o b e s h a l l be
used f o r t h e d e t e c t i o n o f p i n h o l e s i n c o a t i n g s and l i n i n g s o f t t i i c k n e s s less t h a n 500 pm. A h i g h - v o l t a g e
h o l i d a y d e t e c t o r s h a l l h e u s e d f o r t h e d e t e c t i o n of h o l i d a y s and p i n h o l e s i n c o a t i n g s and l i n i n g s o f
t h i c k n e s s g r e a t e r t h a n 500 um o r , i f approved, o f t h i c k n e s s g r e a t e r t h a n 250 pm.
b ) -thickness test. The t h i c k n e s s of t h e c o a t i n g s h a l l be d e t e r m i n e d by a n approved means.
c ) T e s t f o r c o m p l e t e n e s s of c u r e o f c o a t i n g . C o t t o n wool swabs, soaked i n methyl e t h y l k e t o n e , s h a l l b e
p l a c e d on t h e c o a t i n g f o r 5 min. The swabs s h a l l t h e n b e removed and t h e c o a t i n g examined f o r s i g n s o f
unacceptable softening.
d ) O t h e r tests. Any o t h e r t e s t ( s ) t h a t t h e E n y i n e e r may c o n s i d e r n e c e s s a r y , s u c h as t h e d e t e r m i n a t i o n o f
a d h e s i o n by a p u l l - o f f or o t h e r approved method.
0. MEASUREMENT AND PAYMENT

8.1 GENERAL. E x c a v a t i o n and b a c k f i l l i n g of t r e n c h e s , and l a y i n g o f medium-pressure p i p e l i n e s , w i l l b e
measured s e p a r a t e l y under SABS 1200 DB and 8.2, r e s p e c t i v e l y . A t t e n t i o n is drawn p a r t i c u l a r l y t o
5.1.4.1, i n terms o f which no payment w i l l b e made f o r d e p t h s o f e x c a v a t i o n i n e x c e s s o f 1,5 m u n l e s s a
g r e a t e r d e p t h i s shown on t h e d r a w i n g s , or is r e q u i r e d i n terms of t h e p r o j e c t s p e c i f i c a t i o n , o r h a s been
o r d e r e d i.n w r i t i n g by t h e E n g i n e e r .
8.2 SCHEDULED ITEMS

8.2.1 S u p p l y , Lay, and Bed P i p e s Complete w i t h C o u p l i n g 2 ....................................... Unit: m
P i p e l i n e s w i l l b e measured by l e n g t h o v e r a l l l e n g t h s as l a i d . N o d e d u c t i o n w i l l b e made f o r s p e c i a l s
and v a l v e s . S e p a r a t e items w i l l b e s c h e d u l e d f o r e a c h d i a m e t e r and e a c h t y p e and class o f p i p e l a i d .
The rates s h a l l c o v e r t h e cost o f t h e p r o v i s i o n of t h e p i p e s c o m p l e t e w i t h c o u p l i n g s , and t h e costs of
t h e h a n d l i n g , i n s p e c t i n g , t r a n s p o r t i n g , b e d d i n g , l a y i n g , j o i n t i n g , c u t t i n g , t e s t i n g a n d , when r e l e v a n t ,
d i s i n f e c t i n g of t h e p i p e s and t h e j 0 i n t . s . ( S e e 8.2.4.)
8.2.2 Extra-over 8.2.1 f o r t h e S u p p l y i n g , Laying, and Bedding o f S p e c i a l s Complete w i t h C o u p l i n g s
.......................................................................................... Unit: N o .
8.2.3 ........................
E x t r a - o v e r 8.2.1 f o r t.he S u p p l y i n g , F i x i n g , and Bedding o f V a l v e s Unit: No.
S p e c i a l s and v a l v e s w i l l b e measured by t h e number o f e a c h t y p e , c l a s s , and s i z e .
The r a t e s , which s h a l l b e e x t r a - o v e r t h e rates f o r 8.2.1, s h a l l c o v e r t h e cost o f t h e p r o v i s i o n o f e a c h
s p e c i a l o r v a l v e , complete w i t h c o u p l i n g s , and t h e cost o f t h e h a n d l i n g , f i x i n g , b e d d i n g , and t e s t i n y of
t h e s p e c i a l o r v a l v e , as a p p l i c a b l e , and t h e c u t t i n g of t h e p i p e s .
No e x t r a payment o v e r and above t h e rates w i l l b e made i n respect o f any a d d i t i o n a l c u t t i n g , t u r n i n g , and
j o i n t i n g o f p i p e s r e q u i r e d f o r t h e l o c a t i o n o f v a l v e s , s p e c i a l s , etc., i n t h e p o s i t i o n s g i v e n on t h e
drawings.
U n l e s s s p e c i f i c p r o v i s i o n i s made i n t h e s c h e d u l e , no s e p a r a t e payment w i l l b e made f o r t h e s u p p l y and
f i t t i n g o f any a d d i t i o n a l j o i n t s and j o i n t i n g materials which may be r e q u i r e d f o r t h e c o n n e c t i o n of
shortened pipe lengths.
13 SABS 1200 L-1?83

Medium-pressure pipelines
8.2.4 Extra-over 8.2.1 for the Cutting of the Pipe and the Supplying and Fixing
of the Extra Coupling ....................................................................
Unit: No.
Separate items will be scheduled for each size of pipe.
The rate shall cover the cost of the cutting of the pipe and of the supplying and fitting of the
additional coupling and of the delivery of unused off-cuts of pipes to the Engineer's office or store.
8.2.5 supply and Place Pipes, Valves, and Specials (Short pipe runs) ...........................
Unit: No.
Short pipe runs that include frequent bends or other specials, or both (as, for instance, in a pump
station, an intake tower, or a deviation of a major water main under a road or round a bridge) will be
measured in terms of the quantities of scheduled items such as bends, tees, reducers, valves, and stated
lengths (or stated approximate lengths) of straight pipe.
The rate shall cover the provision of each pipe, special, and valve and, as applicable, the fixing.
anchoring, or bedding of them in the manner shown on the drawings or required in terms of the project
specification.
8.2.6 Extra-over 8.2.1 or 8.2.2 or 8.2.3 for supplying and installing joints with machined collars an<
special couplings ........................................................................Unit: NO.
Details of the special couplings required will he given in the schedule.
The rate shall cover the additional cost of providing pipes with machined collars and slip-on couplings
as scheduled, and of installation complete as in 8.2.1 or 8.2.2 or 8.2.3.
8.2.7 Extra-over 8.2.1 for Encasing Joints .....................................................
Unit: NO.
Where wrapping or protection of joints, etc. in terms of 3.9.6 is ordered, payment will be made as an
extra-over per joint.
The rate shall cover the cost of the material, plant, and labour necessary for the completion of the
joint.
8.2.8 Recover Old Pipeline (depth range stated) ...............................................
Unit: m
The toLa1 length of the pipeline ordered to be recovered will be measured by length for each stated depth
range. No deduction will be made for valves, specials, and the like.
The rate shall cover the cost of the excavation and removal of the pipes, valves, and fittings from the
trench, the handling and transporting to the Contractor's store on Site, the cleaning and listing of the
salvaged recovered materials, and the backfilling of the trench.
8.2.9 a) Test recovered pipes on site before relaying ..........................................
Unit: No.
The rate shall cover the cost of the provision of suitable testing equipment and the carrying out of the
specified test.
b) Relay pipeline ........................................................................Unit: m
The rate shall cover the cost of transporting, handling, laying, and bedding, as well as the provision of
new rubber rings or insertions, as the case may be. Couplings and bolts that have to be replaced will be
paid for at daywork rates unless a suitable item such as (c) below has been provided in the schedule or,
in the opinion of the Engineer, the need for their replacement arose from the fault or negligence of the
Contractor.
c) Joints and couplings for recovered pipeline (Provisional) .............................
Unit: No.
The rate shall cover the provision of complete sets, each comprising a new rubber ring or insertion, as
the case may be, as well as all elements of the coupling and bolts that need replacement.
8.2.10 Temporary Valves, etc. ...................................................................
Unit: No. or Sum
Payment for the supply or loan of temporary valves, end caps, blank flanges, or other isolating devices
ordered by the Engineer in terms of 7.3.1.1 will be made at daywork rates or at a price to be agreed by
the Engineer, unless the method of payment for the work has been dealt with in the project specification
and a suitable item included in the schedule.
8.2.11 Anchor/Thrust Blocks and Pedestals
a) Dimensions stated or given on drawing .................................................
Unit: No. or Sum
OR
h ) Where, at the tender stage, no detailed drawings or dimensions are given or where only typical
drawings are given:
Concrete.................................................................................. Itnit: m 3
Formwork. ................................................................................. [Jnit: m 2
Heiriforcement............................................................................. unit: t
Except where measured by number or sum, anchor/thrust blocks and pedestals will be measured as the volume
of concrete, area of formwork, and mass of reinforcement, as relevant, placed to dimensions ordered or
given on the drawings and schedules of reinforcement. The relevant terms of Clause 8 of SABS 1200 ti or
SABS 1200 GA, as applicable, shall apply.
Where measured by number or sum, the rate or sum shall cover the cost of excavation and trimming,
formwork, reinforcement (if any), and screeding of top surfaces.
8.2.12 Concrete Casing .......................................................................... unit: m 3
The concrete will be measured net by volume to the specified width and depth in excess of the external
volume of the pipe (i.e. the volume of the pipe will be deducted).
The rate shall cover the cost of formwork (including stop ends at flexible joints) and concrete.
8.2.13 Valve and Hydrant Chambers, etc. .........................................................
unit: No.
Valve and hydrant chambers, manholes, etc., will be measured as complete units.
The rate shall cover additional excavation (see Subclauses 8.2.2 and 8.2.3 of SADS 1200 L I B ) , materials,
plant, and labour necessary for the complete construction including the installation of the surface boxes
or covers.
8.2.14 a) Manholes .............................................................................. unit: NO.
Manholes will be measured as complete units for which separate items will be scheduled for each type of
manhole of overall depth not exceeding 1.5 m.
The rate shall cover additional excavation, materials, plant, and labour necessary for the complete
construction including the installation of the covers.
b) Extra-over far manholes of depth exceeding 1 . 5 .......................................
Unit: 0,25 m or Sum
Additional depths of manholes in excess of 1,s m will be measured or given in increments of 0.25 m depth
for each type of manhole.
The rate shall cover the cost of complete construction of each extra 0.25 m additional depth or, where
the unit is a sum, such sum shall cover the complete construction to the total extra depth stated or
given on a designated drawing.
8.2.15 Special Wrapping in Corrosive Soil (diameter and location stated) .........................
unit: m
The rate shall cover the cost of the provision and fixing of the wrapping and the cost of any delay and
inconvenience cauqed by the requirement to wrap.
14
SABS 1200 1,-1983
Medium- pr es s lire pipe l i n e s
FINISHED LEVEL IN ROADS, SIDEWALKS,

AND OTHER PAVED AREAS GROUND LEVEL IN UNPAVED
VALVE BOX TYPE 3A TO SABS 558 -
I : 2 MORTAR BACKING
2 2 0 mm BRICKWORK
IN 1:3 MORTAR
BACKFILLING TO BE
THOROUGHLY
COMPACTED ABOVE
PlPE TO BELOW
BRICKWORK BAS
V
"
,.,.,
OZ
22
- -
Lu-w-w
TO SlJlT VALVE
NOTE
a ) For valves OT nominal b m greater than
Dimensions in millimetres. 200 mm $33 relevant detail drawings.
b) See 5.6.2.
Drawing L - I - Detail of Valve Chamber for a Valve of Nominal Bore

not exceeding 200 mm
15
SABS 1200 L-1983
Medi urn-=pres sure pipe l i n e s
375 mm x 300mm HYDRANT VALVE BOX

- TYPE 5 TO SABS 558
(INTERNAL DIMENSIONS OF HYDRANT
CHAMBER 420 Nn x 345 mm)
FINISHED LEVEL IN ROADS,

SIDEWALKS, AND O T H E R 1
PAVED AREAS GROUND LEVEL IN
UNPAVED AREAS
MORTAR BACKING
TYPICAL 65mm HYDRANT VALVE

WITH GUNMETAL OUTLET PIECE.
SCREWED " ROUND' THREAD
DOUBLE-FLANGED C I DISTANCE PIECE

IF NECESSARY TO RAISE THE OUTLET
TO WITHIN 400 mm OF THE TOP OF
THE VALVE BOX
IlOmm BRICKWORK IN l:3 MORTAR
UGHLY
BEU)W
HYDRANT TEE IN WATER MAIN

NOTE
a 1 Test completed chamber with
hydrant standpipe after
fitting cover in position.
b 1 See 5.6.2.
Dimensions in millimetres
Drawing L-2 -Detail of Brick Hydrant Chamber
375 mm x 300 mm HYDRANT VALVE BOX

TYPE 5 TO SABS 558
(INTERNAL DIMENSIONS OF HYDRANT
CHAMBER 420 mm x 345 mm)
FINISHED LEVEL I N ROADS,
SIDEWALKS, AND OTHER U.
PAVED AREAS
GROUND LEVEL IN
- UNPAVED AREAS
MORTAR BACKING
TYPICAL 65 mm HYDRANT VALVE

WITH GUNMETAL OUTLET PIECE.
SCREWED "ROUND" THREAD
DOUBLE-FLANGED CI DISTANCE PIECE

IF NECESSARY TO RAISE THE OUTLET TO
WITHIN 400 mm OF THE TOP OF THE
VALVE BOX
110 mm BRICKWORK
IN I :3 MORTAR
=c BACKFIL.LING TO BE THOROUGHLY
COMPACTED ABOVE PIPE TO BELOW
-
$ BRICKWORK BASE
I
HYDRANT TEE IN WATER MAIN 2 NOT E
a) Test completed chamber with
hydrant standpipe after fitting
Dimensions in millimetrer cover in position.
b) See 5.6.2
Drawing L-3-Detail of Precast Hydrant Chamber
17 LiARS 1 2 0 0 I.-] 983

Medium-pressure pipe1 ines
APPENDIX A. APPI.lCAHLE STANIJARDS
Reference is made to the latest issues of the ioJlowing standards:
AP1 1104 Standard for welding pipelines and related facilities

RS 486 Asbestos-cement pressure pipes and joints
BS 534 Steel pipes and specials for water and sewage
BS 1247 Manhole step irons
BS 2035 Cast iron flanged pipes and flanged fittings
BS 4416 Method for penetrant testing of welded or brazed joints in metals
BS 4504 Flanges and bolting for pipes, valves and fittings. Metric series
Part I : Ferrous
BS 4772 Ductile iron pipes and fittings
SABS 62 Steel pipes and pipe fittings up to 1 5 0 mm nominal bore suitable for screwing to IS0 H7 pipe
threads
SABS 135 tSO metric black bolts, screws, and nuts (hexagon and square)
SABS 136 IS0 metric precision hexagon-head holts, screws, and nuts (coarse thread medium fit series)
SARS 227 Burnt clay masonry units
SARS 285 Calcium silicate masonry units
SAW 2R6 Asbestos cement pressure pipes (constant outside diameter type)
SARS 533 Black polyethylene pipes for the conveyance of liquids
SAW 546 Cast iron fittings for asbestos cement pressure pipes
SABS 558 Cast iron surface boxes and manhole and inspection covers and frames
SABS 676 Reinforced concrete pressure pipes
SABS 677 Concrete non-pressure pipes
SABS 719 Electric welded low carbon steel pipes for aqueous fluids (ordinary duties)
SARS 763 Hot-dip (galvanized) zinc coatinqs (other than on continuously zinc-coated sheet and w l i e )
SABS 946 Asbestos cement pressure pipes (constant internal diameter type)
SABS 966 Components of unplasticized polyvinyl chloride (uPVC) pressure pipe systems
SABS 974 Rubber joint rings (non-cellular)
Part I : Joint rings for use in gas, water, sewer, and drainage systems
SABS 975 Prestressed concrete pipes
SARS 1109 Is0 pipe threads for pipes and fittings where pressure-tight joints are made on the threads
SAHS 1123 steel pipe flanges
SABS 1130 Glass fibre reinforcing material for pipe wrapping
SAHS 1137 Hot-applied bitumen for steel pipeline protection
SARS 1200 A Civil engineering construction : General
SARS 1200 AA Civil engineering construction : General (small works)
SABS 1200 D Civil engineering construction : Earthworks
SABS 1200 DA Civil engineering construction : Earthworks (s~allworks)
SABS 1200 DB Civil engineering construction : Earthworks (pipe trenches)
SABS 1200 G Civil engineering construction : Concrete (structural)
SABS 1200 GA civi 1 engineering construction : Concrete (small works)
SARS 1200 LR Civil engineering construction : Bedding (pipes)
SABS 1200 LK Civil engineering construction : Valves (medium-pressure) (In course of preparation)
SABS 1294 Precast concrete manhole sections and slabs
SABS 0102 The structural design and installation of precast concrete pipelines
SIS 05 59 00 Pictorial surface preparation standards for painting steel surfaces
ISBN 0826-06424-4

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© SABS.

SOUTH A F R I C A N BUREAU O F STANDARDS

Clause rage Number

Clause Page Clumber

Drawing I.. 1 .D e t a i l ..........- 1 4

APPENDIX A . APPLICABLE STANDARDS ................................................................. 17

SO~ITIIAFRICAN BUREAU OF STANDARDS

3.4 s m E L PIPES, FITTINGS, AND SPECIAIS

3.5 CONCRETE PRESSURE PIPES. U n l e s s o t h e r w i s e s c h e d u l e d , c o n c r e t e p r e s s u r e p i p e s s h a l l comply w i t h t h e

3.6 PRESTRESSED CONCRETE PIPES. P r e s t r e s s e d c o n c r e t e p i p e s s h a l l comply w i t h t h e r e q u i r e m e n t s o f S A W 975

3.7 OTHER TYPES OF PTPES

3.8 JOINTING MATERIALS

3.9 CORIIOS ION FR(YPl?CTION

3.10 VALVES. U n l e s s o t h e r w i s e s t a t e d i n t h e project s p e c i f i c a t i o n , v a l v e s s h a l l comply w i t h t h e requiremerlts

3.11 MANHUI.I?S AtJD SURFACE DOXKS

4.2 SETTING OUT. The C o n t r a c t o r may u s e a n y a c c e p t a b l e d e v i c e , i n c l u d i n g o n e i n c o r p o r a t i n g a laser beam, t o

4.3 TESTING. The C o n t r a c t o r s h a l l p r o v i d e a l l t h e equipment, m a t e r i a l s , t o o l s , and f i t t i n g s r e q u i r e d f o r t h e

5.1.4.3 Tlie minimnm c l e a r a n c e bctwcwn t h e o u t s i d e of a p i p e l i n e h e i n q l a i d and t h e o u t - s i d e of any o t h c r 4 > 1 i v L l i a t

5.2 JOINTLNG METllODS

5.3 SETTING OF VALVES, SPECIALS, AND FITTINGS. f l n l e s s o t h e r w i s e s p e c i f i e d or d i r e c t e d , g a t e v a l v e s s h a l l b e

5.4 CONCRETE CASING. Where t h e E n g i n e e r r e q u i r e s p i p e s t o be e n c a s e d , a s t r e n g t h 1 5 MPa/37,5 mm, or s u c h

5.5 ANCHOH/TIIRUST 131,OCKS AND PEDESTAIS. A t tees, b e n d s , termirial v a l v e s , e n d c a p s , arid where t , t h e r w i s e

5.6 VALVE AND HYDI<ANT C1lAMHE;RS

5.10 DISINFECTION OF PO'I'AHLB WATER PIPELINES. On c o m p l e t i o n of t h e l a y i n g and t e s t i n g , e a c h p o t a b l e water

7.2 INITIAL TESTS ON WELDED STEEL PIPES

7.3 STANDARD HYDRAULTC PIPE TEST

SARS 1200 L-1983 12

7.3.1.4 The f i e l d t e s t p r e s s u r e shall n o t e x c e e d t h e a p p r o p r i a t e of t h e f o l l o w i n g v a l u e s :

7.4 TESTS ON EPOXY COATINGS. The C o n t r a c t o r s h a l l c a r r y 'out t h e f o l l o w i n g tests on epoxy c o a t i n g s o n steel

0. MEASUREMENT AND PAYMENT

8.2 SCHEDULED ITEMS

13 SABS 1200 L-1?83

FINISHED LEVEL IN ROADS, SIDEWALKS,

VALVE BOX TYPE 3A TO SABS 558 -

Drawing L - I - Detail of Valve Chamber for a Valve of Nominal Bore

375 mm x 300mm HYDRANT VALVE BOX

FINISHED LEVEL IN ROADS,

TYPICAL 65mm HYDRANT VALVE

DOUBLE-FLANGED C I DISTANCE PIECE

IlOmm BRICKWORK IN l:3 MORTAR

HYDRANT TEE IN WATER MAIN

Drawing L-2 -Detail of Brick Hydrant Chamber

375 mm x 300 mm HYDRANT VALVE BOX

TYPICAL 65 mm HYDRANT VALVE

DOUBLE-FLANGED CI DISTANCE PIECE

Drawing L-3-Detail of Precast Hydrant Chamber

17 LiARS 1 2 0 0 I.-] 983

APPENDIX A. APPI.lCAHLE STANIJARDS

Reference is made to the latest issues of the ioJlowing standards:

AP1 1104 Standard for welding pipelines and related facilities

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