MAIN ROADS TECHNICAL STANDARD

MRTS29 Polyethylene Pipes

November 2011

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IMPORTANT INFORMATION
The requirements of this document represent Technical Policy of the department and contain Technical Standards. Compliance with the departments Technical Standards is mandatory for all applications for the design, construction, maintenance and operation of road transport infrastructure in Queensland by or on behalf of the State of Queensland. This document will be reviewed from time to time as the need arises and in response to improvement suggestions by users. Please send your comments and suggestions to the feedback email given below.

FEEDBACK
Your feedback is welcomed. Please send to mr.techdocs@tmr.qld.gov.au. DISCLAIMER This publication has been created for use in the design, construction, maintenance and operation of road transport infrastructure in Queensland by or on behalf of the State of Queensland. Where the publication is used in other than the departments infrastructure projects, the State of Queensland and the department gives no warranties as to the completeness, accuracy or adequacy of the publication or any parts of it and accepts no responsibility or liability upon any basis whatever for anything contained in or omitted from the publication or for the consequences of the use or misuse of the publication or any parts of it. If the publication or any part of it forms part of a written contract between the State of Queensland and a contractor, this disclaimer applies subject to the express terms of that contract. COPYRIGHT Copyright protects this publication. Except for the purposes permitted by and subject to the conditions prescribed under the Copyright Act, reproduction by any means (including electronic, mechanical, photocopying, microcopying or otherwise) is prohibited without the prior written permission of the department. Enquiries regarding such permission should be directed to the Contracts and Technical Capability Branch, Queensland Department of Transport and Main Roads. State of Queensland (Department of Transport and Main Roads) 2011

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Department of Transport and Main Roads Technical Standard

MRTS29 Polyethylene Pipes

Table of Contents
Page 1 2 3 4 4.1 5 5.1 5.2 6 INTRODUCTION ....................................................................................................................................1 DEFINITION OF TERMS........................................................................................................................1 REFERENCED DOCUMENTS...............................................................................................................1 QUALITY SYSTEM REQUIREMENTS ..................................................................................................1 Hold Points .........................................................................................................................................1 DESIGN ..................................................................................................................................................2 Design Requirements .........................................................................................................................2 Design Life..........................................................................................................................................3

MANUFACTURE AND SUPPLY ............................................................................................................3 6.1 Manufacture........................................................................................................................................3 6.2 Materials .............................................................................................................................................3 6.3 Information to be Supplied by Contractor...........................................................................................4 6.3.1 Prior to Delivery of Pipes to the Site...............................................................................................4 CONSTRUCTION...................................................................................................................................4 7.1 Construction........................................................................................................................................4 7.2 General ...............................................................................................................................................4 7.2.1 Bedding of Pipe Components.........................................................................................................5 7.2.2 Assembling Pipe Components .......................................................................................................5 7.2.3 Laying and Jointing Pipe Components...........................................................................................5 7.2.4 Backfilling and Compaction ............................................................................................................5 7.2.5 Horizontal Tolerances.....................................................................................................................5 7.2.6 Vertical Tolerances.........................................................................................................................5 7.2.7 Diametral Tolerances .....................................................................................................................6 8.1 8.2 8.3 8.4 COMMENTARY......................................................................................................................................6 General ...............................................................................................................................................6 The 100y Service Life Design Parameters.........................................................................................6 Materials .............................................................................................................................................6 Criteria for Evaluation of Other Products............................................................................................6

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Department of Transport and Main Roads Technical Standard

MRTS29 Polyethylene Pipes

Polyethylene Pipes
1 INTRODUCTION
This specification applies to flexible pipes conveying water, stormwater or slurry in non-pressure applications, or as conduits for latter installation of cables or pipes. This specification is applicable to flexible pipes, manufactured from homogeneous or composite (steel reinforced) High Density Polyethylene (HDPE) as defined in AS/NZS 4131. This Standard shall be read in conjunction with MRTS01 Introduction to Technical Standards, MRTS50 Specific Quality System Requirements and other Technical Standards as appropriate. This Technical Standard forms part of the Main Roads Specifications and Technical Standards Manual.

DEFINITION OF TERMS

The terms used in this specification shall be as specified in Clause 3 of MRTS 01 Introduction to Standard Specifications.

REFERENCED DOCUMENTS

Table 1 lists documents referenced in this Technical Standard Table 1 Referenced Documents Reference AS/NZS 2666.1 and 2 AS/NZS 5065 ASTM F2562/F2562M-8 AS/NZS 4131 Buried flexible pipelines Polyethylene and polypropylene pipes and fittings for drainage and sewerage applications Specification for steel reinforced thermoplastic ribbed pipe and fittings for non-pressure drainage and sewerage Polyethylene (PE) compounds for pressure pipes and fittings Title

4
4.1

QUALITY SYSTEM REQUIREMENTS

Hold Points

General requirements for Hold Points, Witness Points and Milestones are specified in Clause 5 of MRTS01 Introduction to Standard Specifications. The Hold Points and Milestones applicable to this specification are summarised in Table 2. Table 2 Hold Points Clause 5.1 7.2 7.2.3 Hold Point 1. Design requirements 2. Construction 3. Laying and jointing pipe components Milestone Submit detailed drawings and design certificate for approval no less than 14 days before ordering pipes Submit pipe laying procedure for approval no less than 14 days before installation Approval of joints and fittings

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MRTS29 Polyethylene Pipes

Department of Transport and Main Roads Technical Standard

5
5.1

DESIGN
Design Requirements

Where the design of polyethylene pipes is to be undertaken by the Contractor, the Contractor shall submit to the Superintendent for approval in accordance with Clause 37 of the Supplementary Conditions of Contract, detailed drawings and a Design Certificate for the pipes Milestone. The drawings shall clearly show details of the pipe alignment and levels, bedding and surround details, bends, fittings, joint details, if any, and the live load pressure distribution and maximum applied at the crown that has been assumed. Drawings and the Design Certificate shall be certified as complying with this specification by a Registered Professional Engineer, Queensland. The Contractors Design shall be documented in a Design Report, the Contractors Construction Drawings and the Contractors Construction Specifications and shall include a floatation check as well as definition of the installation sequence. Installation of pipes shall not commence until the Contractor has been granted permission to use the pipes in accordance with Clause 37 of the Supplementary Conditions of Contract Hold Point 1. Design of polyethylene drainage pipes shall conform to this specification and AS/NZS 2566.1. The design characteristics shall be based on AS 2566.1 amended as follows: The Table 2.1 of the Standard shall be modified as shown in Table 3 below: Table 3 Typical pipe material characteristics Pipe material Max allowable longterm hoop stress h all Long-Term Ringbending Modulus EbL MPa 194 199 252

PE 80B PE80C PE 100

6.3 6.3 7.5

a) Clause 4.7.2 of AS 2566.1 shall be deleted and replaced by: a. Loads shall be calculated in accordance with the methods in AS 5100; b. Design loads for pipes are W80, A160, SM1600 and HLP 400; and c. Distribution of live loads shall be in accordance with AS 5100;

b) Figures 4.1 to 4.2 of AS 2566.1 are deleted; and c) Live load pressures shall be as detailed in Table 4.

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Department of Transport and Main Roads Technical Standard Table 4 Live Load Pressure for AS 5100 highway Loads Depth (m) 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00 2.20 2.40 2.60 2.80 3.00 3.20 3.40 3.60 Wheel Load Pressure (kPa) 129 78 52 39 30 24 23 22 21 20 19 19 18 17 17 16 Depth (m) 3.80 4.00 4.20 4.40 4.60 4.80 5.00 5.20 5.40 5.60 5.80 6.00 6.20 6.40 6.60 6.80 Wheel Load Pressure (kPa) 16 15 15 14 14 13 13 12 12 12 11 11 11 11 10 10 Depth (m) 7.00 7.20 7.40 7.60 7.80 8.00 8.20 8.40 8.60 8.80 9.00 9.20 9.40 9.60 9.80 10.00

MRTS29 Polyethylene Pipes Wheel Load Pressure (kPa) 10 9 9 9 9 9 8 8 8 8 8 7 7 7 7 7

5.2

Design Life

The design life of polyethylene drainage pipes shall be 100 years. The design life means that 95% of the production shall remain in a serviceable condition with negligible maintenance for 100 years.

6
6.1

MANUFACTURE AND SUPPLY

Manufacture

The manufacture of polyethylene drainage pipes shall be covered by a third party accredited quality assurance system that complies with AS/NZS ISO 9001. Pipes shall be manufactured only by a Transport and Main Roads registered manufacturer. For the requirements for registration and information regarding Transport and Main Roads' registered manufacturers refer to Director (Bridge Design) Queensland Department of Transport and Main Roads GPO Box 1412 Brisbane Qld 4001

6.2

Materials

Material used in the manufacture of polyethylene drainage pipes and pipe performance requirements shall comply with AS/NZS 5065 Polyethylene and polypropylene pipes and fittings for drainage and sewerage applications. The compliance with AS/NZS5065 and minimum sampling and testing frequency plan shall be as defined in Appendix A of the above Standard. In addition, steel reinforced composite polyethylene pipes shall comply with ASTM F2562/F2562M. Steel reinforcement in composite pipes shall be fully encapsulated within the polyethylene.
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MRTS29 Polyethylene Pipes

Department of Transport and Main Roads Technical Standard

Only black HDPE pipes with carbon black content as per AS/NZS 5065 are permitted. Concrete in end blocks shall comply with the requirements specified in Clause 6.1 of MRTS03 Drainage, Retaining Structures and Protective Treatments, except that the maximum aggregate size shall not exceed 9.5 mm. Concrete infill material shall consist of 1 part of Type GP cement to 10 parts aggregate (loose volume). The maximum aggregate size shall be 9.5 mm.

6.3

Information to be Supplied by Contractor

The Contractor shall provide to the Superintendent the following information, obtained from the manufacturer and included in the quality records.

6.3.1

Prior to Delivery of Pipes to the Site

The following information shall be provided if requested by the Superintendent, before any pipes are delivered to the Site. This information shall also be permanently marked on the inside of the pipe in accordance with AS/NZS 2566.2 a) Manufacturers name or registered Trademark or both. b) Nominal size in the form DN 110, as appropriate. c) Class in the form, SN 1.25, SN 2, SN 4, SN 8, SN 10, SN 16, or as applicable. d) For plain wall pipes, the SDR, in the form SDR 17, as appropriate. e) The letters PE. f) For structural wall pipes of sandwich construction the letters 'SC'. g) Date of manufacture, in the form 060515 (i.e. the 15th May 2006), as appropriate. h) Identification of place of manufacture. The manufacturers code is acceptable. With each batch of pipes delivered to the site the Contractor shall provide a conformance report, issued by the pipe manufacturer, confirming that the pipes supplied comply with the requirements of AS/NZS 5065 and this specification, MRTS29.

7
7.1 7.2

CONSTRUCTION
Construction General

Construction shall conform to the requirements of AS/NZS 2566.2. Prior to construction, the Contractor shall check the construction loads which will be placed on the pipe by the proposed construction procedure and equipment. Laying of pipes shall not commence until the procedure has been approved by the Superintendent. Hold Point 2. Polyethylene pipe components shall be installed in the locations and in accordance with the details shown on the Drawings. Pipes shall normally be installed up grade. Pipes shall have a positive drainage slope along their whole length and, where relevant, shall join neatly to existing structures. The Contractor shall set out the drainage structure in accordance with the details shown on the Drawings. The provisions of Clause 9 of MRTS01 Introduction to Standard Specifications shall apply to the set out procedure. Excavations necessary to allow installation of the pipe components shall be carried out in accordance with Clause 14 of MRTS04 General Earthworks and to meet the embedment zone requirements of AS/NZS 2566.2 Clause 4.4.

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Department of Transport and Main Roads MRTS29 Technical Standard Polyethylene Pipes Unsuitable material shall be identified according to MRTS04 Cl 10 Unsuitable material, and removed from site. Concrete work shall comply with the requirements specified in Clause 6.1 of MRTS03 Drainage, Retaining Structures and Protective Treatments.

7.2.1

Bedding of Pipe Components

Foundation, bedding and haunch zone materials shall be placed in accordance with the requirements of AS/NZS 2566.2. The foundation and bedding shall provide continuous even support to the pipe components. The maximum particle size and grading limits for the embedment materials shall comply with Cl 5.4.2 of AS/NZS 2566.2. The material in the embedment zone shall consist of: a) Selected cohesionless soils (refer Appendix G) b) Controlled low strength materials (refer Appendix K) c) Stabilised soils (refer Appendix L) Where Embankment Installation Condition is specified, prior to commencing placing bedding and laying pipes, place and compact fill to the height of the top of the side support zone. Where Trench Installation Condition is specified for pipes in an embankment, complete the embankment to the top of the embedment zone prior to the commencement of excavations.

7.2.2

Assembling Pipe Components

shall be assembled in accordance with the manufacturers drawings and

Pipe components recommendations.

7.2.3

Laying and Jointing Pipe Components

Where possible, laying of pipe components shall commence at the outlet end of the pipe and progress to the inlet end. Pipes with socket connections shall be laid with sockets upstream. Pipes shall be installed ideally in single lengths without joints and joints shall not be used without prior approval of the Superintendent. Where joints are required, they may be either welded or mechanical but shall form a watertight seal that has the same stiffness, structural strength and durability of the pipe without compromising hydraulic efficiency. Hold Point 3 Where necessary, components shall be selected and arranged to give best fit. The ends of components shall be free of any foreign matter at the time of jointing.

7.2.4

Backfilling and Compaction

Backfilling and compaction shall be carried out in accordance with the requirements of AS/NZS 2566.2 including Appendix H.

7.2.5

Horizontal Tolerances

The horizontal alignment of pipes shall not vary from that specified by more than the limits stated in Clause 3 of Annexure MRS03.1 or, if no limits are stated, + 100mm.

7.2.6

Vertical Tolerances

The invert heights of pipes shall not vary from those specified by more than + 10mm, provided always that nowhere shall the grades depart from those specified by more than 1% (absolute). Notwithstanding these tolerances, the minimum thickness of cover over pipes shall nowhere be less than 600mm.

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MRTS29 Polyethylene Pipes

Department of Transport and Main Roads Technical Standard

7.2.7

Diametral Tolerances

The short-term vertical deflection of polyethylene and steel reinforced polyethylene (SRP) pipes at 30 days from completion of placement and compaction of all trench and embankment fill material shall comply with Table 5.6 of AS/NZS 2566.2. The pipes shall be tested with either a rigid prover or a laser profiling technique approved by the Administrator.

8
8.1

COMMENTARY
General

The Commentary provides additional information on the background to the approach adopted in the Standard Specification. The issues covered are determination of 100 years service life design parameters, selection of materials for drainage pipes on TMR projects and procedure for evaluation of materials currently not included in the Specification.

8.2

The 100y Service Life Design Parameters

The 100y design parameters for polyethylene (PE) have been derived from the published tests reports that confirmed consistent 3% reduction of the relaxation modulus when extrapolated from 50 to 100 years. Consequently the values of the long-term ring-bending modulus given in table 2.1 of AS/NZS 2566.1 have been modified accordingly to reflect 100y design parameters.

8.3

Materials

MRTS29 does not cover polypropylene (PP). Polypropylene is specifically excluded from AS/NZS 2566.1 and 2 - Buried flexible pipelines, a basic document governing design and installation of buried plastic pipes. PP exhibits substantially higher creep than PE under the range of stresses common in buried pipes. This characteristic is attributed to the amorphous molecular structure of PP resulting in relaxation curves that cannot be classified as rectilinear. Therefore PE curves cannot be used for deriving PP design parameters. The approach adopted in developing the material design parameters and the criteria for long-term performance have been developed in collaboration with the leading experts in the chemistry of polymers in Australia.

8.4

Criteria for Evaluation of Other Products

Although the specification may appear restrictive, TMR recognise that PP pipes may constitute part of the product range of plastic pipe suppliers and have no intention of excluding polypropylene from the market. The currently developed MRTS29 will be limited to polyethylene pipes however, polypropylene may be considered for future revisions provided the process of developing the long-term design parameters is based on the actual performance of the specific PP resins. The process of incorporating polypropylene to TMR specification must be structured as follows: a) The grades of PP resins proposed for the manufacture of drainage pipes must be identified. The raw material suppliers must determine time dependence of the selected PP resins through testing. Accelerated tests at elevated temperatures would be acceptable. Only rectilinear curves can be used for development of the long-term properties. b) The suppliers must demonstrate that the resins identified for manufacturing of drainage pipes will not develop transition from a ductile to brittle failure within 100y service life. c) PP must be effectively stabilised against UV degradation. If the UV resistance is claimed in the product specification, this attribute must be confirmed by testing at NATA accredited laboratory. The TMR objective is to develop a technical standard that would not unjustly disadvantage any supplier. The objective is to produce a well balanced document where the accepted materials, their design parameters and the expected service life are determined by the methods recognised by the leading authorities in the field.

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