j - ductile iron pillar hydrants

SYABAS’ STANDARD SPECIFICATION FOR PIPE LAYING WORKS First Edition: May 2007

J - DUCTILE IRON PILLAR HYDRANTS 1.0 General 1.1 This specification briefly specifies the requirement for the standard 100mm and 150mm pillar hydrants. 1.2. Pillar hydrants will be of ductile iron material conforming to BS 750 : 1984 or JKR Specification 202000-0042-99. 2.0 Type of Pillar Hydrants 2.1 100 mm diameter Pillar Hydrant

• The 100 mm pillar hydrant shall be designed with 65 mm diameter outlets as shown in Appendix 1 & 2.

• The pressurized 100 mm pillar hydrant shall be equipped with landing valves as in

Appendix 3. 2.2 150 mm diameter Pillar Hydrant

• The 150 mm pillar hydrants is provided with two 65 mm diameter outlets and one 100 mm diameter outlet as in Appendix 4.

• The pressurized 150 mm pillar hydrant is equipped with two 65 mm diameter

landing valve and one 100 mm diameter outlet in Appendix 5 & 6. 3.0 Materials 3.1 Body and Cap: - The body and cap of the pillar hydrants shall be made of ductile (spheroidal graphite) iron at least of quality conforming in all respect to the requirements specified in BS 2789:1985 of Grade 421/12. 3.2 Outlets

• The material for outlets shall be made of die-cast brass which must comply with the standard BS 1400 Grade DCB1 with minimum tensile strength of 210 N/mm².

• The screwed outlets shall be provided with caps to cover the outlet thread.

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• The caps shall be securely attached to the hydrant by galvanized steel chain.

• A minimum 3 mm thick rubber gasket conforming to BS 3457 shall be provided.

• The screwed outlets shall be locked to prevent theft by using pins as shown.

3.3 Landing Valve: - The materials used for all the components of the landing valve are as shown and must comply with BS 5041 Part :1987. 4.0 Dimensions 4.1 Body 4.1.1 100 mm Pillar Hydrant

• Overall height 827 mm ± 10 mm

• External diameter of hydrant 130 mm ± 5 mm

• Internal diameter of hydrant 102 mm ± 2.0 mm

• Flange at inlet as specified in Table 11 BS 4504 1989 Section 3.2 for Ductile Iron. 4.1.2 150mm Pillar Hydrants

• Overall height 875 mm ± 10 mm

• External diameter of hydrant 213 mm ± 3 mm

• Internal diameter 150 mm ± 3 mm

• Flange at inlet as specified in Table 11 BS 4504 1989 Section 3.2 for Ductile Iron. 4.2 Outlet 4.2.1 65 mm diameter Outlet

This outlet is used as the standard outlets for the 100 mm diameter pillar hydrant and as the side outlets of the 150 mm diameter pillar hydrant.

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4.2.2 Outlet diameter

• Internal 64mm + 0.0 mm

- 1.5 mm

• External 75 mm + 0.8 mm - 0.0 mm

• Length of outlet 122 mm ± 1.0 mm

• Thickness of flange 10 mm ± 1.5 mm

• Diameter of flange 96 mm ± 1.0 mm

• Length of thread 35 mm ± 1.0 mm

• Diameter of thread 35 mm ± 0.4 mm

(External) • Type of threads V - Threads

• Threads per 25.4 mm 5 1/3 Nos

4.2.3 100 mm diameter Outlet

For the front outlet for all 150 mm diameter pillar hydrants required dimensions are as follows: -

(i) Outlet Diameter

• Internal 95 mm + 0 mm - 1.5 mm

• External 112 mm + 0.8 mm

- 0 mm (ii) Length of Outlet 126 mm ± 1.0 mm

(iii) Thickness of Flange 12 mm ± 1.5 mm

(iv) Diameter of Flange 140 mm ± 1.0 mm

(v) Length of thread 50 mm ± 1.0 mm

(vi) Type of threads Round Threads (vii) Threads per 25.4 mm 3 Nos.

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4.2.4 Landing Valves

All landing valves shall comply with BS 5041 Pt 1:1987 to be used for the pressurized 100mm pillar hydrant as well as the side outlets of the pressurized 150 mm pillar hydrant.

4.3 Caps

Cap dimension are as follows:

4.3.1 Cap for 65 mm diameter Outlets

• Width of cap 42 mm ± 1.0 mm • External diameter of cap 100 mm ± 2.0 mm • Internal diameter 81 mm ± 0.5 mm • Rubber gasket Min. 3 mm thick

4.3.2 Cap for 100 mm diameter Outlet

• Width of Cap 51 mm ± 1.0 mm • External diameter 210 mm ± 3 mm

• Internal diameter 112 mm ± 0.5 mm • Rubber gasket Min. 3 mm thick

4.4 Chain

• Material to be of galvanized steel.

• Minimum diameter for the link of the chain shall be 5 mm.

• The total minimum length of chain used for 100 mm pillar hydrant.

• 150 mm pillar hydrant shall be 660 mm and 1160 mm respectively.

• Link of galvanized steel chain can be fixed either by attaching to the ear with a 100 mm drill hole or embedding in lug formed in casting.

5.0 Coating 5.1 All machined surfaces shall be thoroughly cleaned and shall be treated with a protective

composition before they become affected by rust.

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5.2 The outer surface of the body shall be coated of either fusion bounded epoxy powder or

approved fire hydrant yellow with minimum thickness 250 µm conforming to AS / NZ 4158.

6.0 Testing 6.1 Hydrostatic Test

• The hydrant is subjected to a hydraulic pressure of not less than 24 bar for a period of not less than 24 bar of a period of not less than 1 minute.

• Overall Flow Test • The hydrant shall deliver not less than 210 liters / min at a constant pressure of 1.7 bar at

the inlet to the hydrant (Results may be obtained by interpolation by referring to the pressure versus flow curve as in Appendix 7).

7.0 Markings Each hydrant shall have the following markings in raised letters of minimum 50 mm high cast on the body.

• The Manufacturer’s name and trade mark

• The size of the hydrant

• The year of manufacture (last two digits)

• The word “SYABAS”

• The body material identification ‘DI’

• Made in Malaysia

8.0 Accessories 8.1 Accessories and fittings associated to pillar hydrants are: -

• Double-flanged duck-foot 90° (¼) bends

• Pipes with cast-on flanges, Class K12

• Valves

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8.2 All fittings such as double-flanged duck-foot 90° (¼) bends and pipes with cast-on flanges,

Class K 12 connecting to the pillar hydrants shall be made of ductile iron. 8.3 All ductile iron fittings shall have the tensile strength of 421 Mpa and minimum elongation

of 5%. 8.4 Coating for fittings (both internally and externally)

• All fitting shall be coated with fusion bonded epoxy powder of not less than 350 µm thickness.

• All bolts, nuts and washers made of hot dipped galvanize zinc plated carbon steel

coated with Rislan Nylon with the finished thickness of coating between 75 µm and 125 µm.

9.0 Flanged joints 9.1 The dimensions and tolerances of the flanges of pipes and fittings shall comply with PN 16

requirement for ductile iron. 9.2 Each fitting shall be supplied with a set of flange jointing materials, which shall be

completed with nuts, bolts, washers and joint rings. 9.3 Joint rings shall be of flat section 5 mm thick, medium rubber reinforced with two-ply

flexible fabric and shall not extend beyond the bolt circle. 10.0 Pre- Delivery Inspection and Evaluation 10.1 It is the responsibility of the Contractor to inform SYABAS Sdn. Bhd. for inspection purposes

during manufacturing and before delivery. 10.2 SYABAS reserved the rights to inspect and witness the testing of product offered. 10.3 At any time, when requested, the Contractor is to provide SYABAS a sample of the product

offered for evaluation purposes. All costs shall be borne by the Contractor. 10.4 If at any time the Contractor fails to deliver the required sample, the product is deemed fail

to meet the specifications. 11.0 Certification 11.1 The Contractor is required to provide a copy of the certificate and testing report from SIRIM,

IKRAM or other recognised certification body. 11.2 Tests report required should be those tests conducted within a year period.

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11.3 SYABAS reserved the rights to refuse offer or reject supply if the documents required are not

enclosed. 12.0 Packaging

All pillar hydrants shall be individually packed with proper methods and protected from damage during transit.

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Appendix 5

Cold Applied High Solid Liquid Epoxy Coatings

On Casting Surfaces (Both Internally and Externally) 1. Surface Preparation All surfaces to be coated shall be clean and dry and free from porosity, crack, sand, rust, oil, grease and other foreign matter. They shall be prepared by abrasive blast cleaning to Sa 2 ½ Standard (ISO 8501–1). Only dry abrasive blasting procedures shall be used. Any clean surface left overnight without coating shall be reblasted before application of coating. In the event rusting occurs after completion of surface preparation due to bad weather, the surface shall again be cleaned in accordance with the specified standard. Cleaning shall be discontinued each day in sufficient time to permit the surfaces cleaned to be coated before rust booming. 2. Coating Application Coatings shall be applied in accordance with Section 3.3 of AWWA C210-84. Application of coating shall be by spraying to a total dry film thickness of more than 356 microns but less than 635 microns. The coating shall not have coating imperfections such as blisters, cracks, bubbles, underfilm voids, mechanical damages, holidays, pinholes or discontinuities. 3. Coating Repair Areas requiring coating repairs due to coating imperfections shall be cleaned using hand and power tool to minimum St 2 Standard (ISO 8501-1). The adjacent coating shall be roughened. All dust shall be wiped off. Same coating material shall be applied to the prepared repair areas immediately to the required thickness. Repairs shall be electrically inspected using a holiday detector. 4. Coating Procedure a. Coating System 1 (one) coat system b. Application Condition :

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Surfaces shall not be coated in rain, wind, fog, mist or in areas where airborne elements exist; when the steel surface temperature is less than 30C above dewpoint; when the relative humidity is greater than 85%. Blast-cleaned surfaces shall be coated as soon as practical, not later than rust booming. c. Paint Application Procedure :

• Mixing, pot life, thinner shall be as per paint manufacture recommendation. • Apply a wet coat in even parallel passes. Overlap each pass 50% to avoid bare

areas pinholes or holidays.

• Thinning normally not required. Thin only for workability with not more than 10% by volume of thinner.

• Check thickness of dry coating with non-destructive dry film thickness gauge.

• In confined areas, observe safety rules provided by paint manufacturer.

• Uncured paint should not be exposed to water, chemicals or mechanical stress

before the paint is fully cured.

• It is recoatable provided that the existing surface is cleaned from oil or other foreign contamination. Prior to recoating all irregular surfaces are to be sand paper abraded.

• For multicoat system, recoating time shall follow paint manufacturer

recommendation.

• Prior to recoating, all irregular surfaces are to be sand paper abraded. 5. Inspection a. Surface Preparation :

Visually (From ST2 to SA 2.5) b. Surface Profile :

The profile height shall be spot checked with Elcometer Profile Gauge or Keane-Tator Comparator with reference to5a. above.

c. Paint Material

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Record batch number d. Metal Temperature

The magnetic metal temperature gauge should be used. Metal temperature must be 30C above the dew point.

e. Wet Film Thickness (WFT) The comb-type gauge shall be used. f. Dry Film Thickness (DFT) The Elcometer DFT Gauge shall be used. g. Visual Inspection

Coats shall be smooth, free from dry spray, pinholes, blisters, craters and excessive sagging.

6. Testing on Applied External and Internal Coating 6.1 ‘Holiday Test’ ASTM G62-87 All pipes shall be checked for continuity of the applied protection in accordance with ASTM G62-87. Discontinuities and pinholes indicated by the test shall be made good as per the manufacturer recommendation. 6.2 Adhesion Test When an adhesion test is carried out, it shall comprised one of the following methods : a. The Ring Test

A ring 75mm wide shall be cut cold from one end of finished pipes. The ring shall be flattened at a temperature between 100C and 210C to 50% of the original diameter. The lining and / or coating shall not part from the metal under this test.

b. The Strip Test Using a tool with a thin sharp blade, two cuts approximately 50mm apart shall be

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made through the protection on the metal pipe. Sudden impact that would cause ultimately separation shall be avoided. The blades shall be worked under the protection and an attempt made to peel it from the metal. The adhesion shall be considered satisfactory if removal of the protection causes cohesive failure and the protection does not peel cleanly from the primer or the pipe surface.

c. Measuring Adhesion by Tape Test – ASTM D 3359-93

Test method A is primarily intended for use at job sites. An ‘X’ cut is made in the film to the substrate, pressure sensitive tape is applied over the cut and then removed, and adhesion is assessed qualitatively on the 0 to 5 scale. The acceptance should be 4A-Trace peeling or removal along incision or at their intersection.

d. Pull-Off Strength of Coating Using Portable Adhesion Testers – ASTM D 4541-93

This test method is for the determination of perpendicular force of the coating can bear a plug of material is detached. It has to be carried on a flat surface. The general pull-off test is performed by securing a loading fixture (dolly) normal (perpendicular) to the surface of the coating with an adhesive. After the adhesive is cured, a testing apparatus is attached to the loading fixture and aligned to apply tension normal (perpendicular) to the test surface. The force applied to the loading fixture is then gradually increased and monitored until either a plug of coating material is detached or a specified value is reached. The acceptance criterion is a minimum strength of 20 kg/cm2.

The tests shall be performed when the protection has been allowed to cure at a temperature not less than 100C or more than 350C for a minimum of 48 hours after application. However for pull-off adhesion test, a proper curing period of 7 days is required before the test.

Note : When an adhesion test is required, this should be stated by the purchaser during enquiring or ordering.

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STANDARD INSPECTION PROCEDURE (BLASTING) A. BEFORE BLASTING 1. Condition of Rust - Grade A, B, C, D To check

2. Oil or grease – solvent wipe in accordance with SSPC-SP1

3. Sharp edges, wedge slag - grind off 1. Grade / Mesh size

To check 2. Salt free and general utility 1. Test run for equipment

To check 2. Compressed air free from oil and moisture – trap and separator

INSPECTION OF CASTINGS

INSPECTION OF ABRASIVE

INSPECTION OF BLASTING EQUIPMENT

3. Pressure at blast hose nozzle - hyperdermix needles (85 –

100psi) 4. No defective on blasting

nozzle

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B. DURING BLASTING To check

1. Measure and record weather condition – dew point, relative humidity, steel surface temperature. No blasting shall be allowed if steel temperature is not at least 30C above dew point

To check 1. Standards achieved – visual

MEASURE AND RECORD WEATHER CONDITION

INSPECTION OF CASTINGS comparison using Pictorial

Standard ISO 8504

2. Surface roughness of minimum 30µ as measured by Keane-Tator surface comparator

Note : 1. No blasting to be allowed if relative humidity is above 85% (Whitling Hygrometer

to be used). Casting surface temperature (using Magnetic Contact Thermometer) is not more than 30C above dew point (using Dew Point Calculator)

2. Blasted casting surfaces should be primed within 4 hours at normal weather

condition provided that no abrupt change in weather condition, and surface (rust blooming).

3. Blasted surfaces left uncoated overnight shall receives a complete light blasting the

next day before priming.

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C. AFTER BLASTING To check

No coating to be applied if casting temperature is less than30C above dew point

To check

1. Sharp edges to be removed by sanding down

2. Dust free surface – to blow off

dust Within 4 hours 3. Dust/pollution free environment

to be applied when blasting work is being carried out nearby

CHECK WEATHER CONDITION

INSPECTION OF CASTINGS

PAINT APPLICATION

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References of Cold-Applied High Solids (solvent or solventless) Epoxy as Internal and External Coating System For Metal Surfaces Suitable For Portable Water

(Using High Solids (solvent or solventless) Epoxy-Based Primer/Topcoat)

Jotun

Dimet Courtaulds Coatings(International Paint)

Nippon Paint

Manufacture Description

Jotamastic 87

Naviguard

Amerlock 400

Amercoat 395

Intergard Potable Water Tank

Coating

Interline 925 Coppon EA-9 Finish HB

Certification

AWWA C210 84 by COT

10 Dec 92

AWWA C210 84/92 by COT

27 Sep 94

Coating System

1 or 2 coats 1 or 2 coats 1 or 2 coats 2 coats Multicoat System Multicoat System 2 coats

Colour

Varieties Varieties Varieties White. Off-White Orange

White, Pink Cream, White Varieties

Solids Volume 82% ± 2% 100% 83% ± 3% 91% ± 3% 56% 100% 55%DFT per Coat 150 - 400µ 150 - 400µ 100 - 210µ 75 - 125µ 125µ 300 - 600µ 150µ

Recommended Total DFT 400µ 400µ 400µ 400µ 400µ 400µ 400µ

Application Method Airless or

Conventional Spray

Airless or Conventional

Spray


Spray


Spray

Airless Spray

Airless Spray


Spray

Drying Period

Touch Dry Hard Dry

Curing

BS 3900 C2 & C3

(350C)

2.5 hrs 5 hrs

3 days

BS 3900 C2 & C3

(350C)

2.5 hrs 4 hrs

3 days

ASTM D1640

(320C)

4.5 hrs 12 hrs 4 days

ASTM 1640

(210C)

6 hrs 24 hrs 7 days

(350C)

1 hrs 3 hrs

-

(350C)

4 hrs 8 hrs

-

(250C - 350C) 2 hrs 16 hrs 9 days

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Appendix 6

Polymeric Coating 1. Materials and Thickness Pipes and fittings shall be coated with either a thermoset or thermoplastic polymeric coating material. The coating shall be applied using either the fluidized bed dipping process or the electrostatic spray process. The minimum thickness of polymeric coating material shall be not less than those specified below : Coating Type Coating Thickness (µm) Thermoplastic 200 – 450 Thermoset 350 – 650 Note : A coating manufacturer may specify higher minimum coating thickness than those specified above 2. Performance Testing

Water Quality

All coating material in contact with or likely to come in contact with potable water shall meet the requirements of BS 6920 Part 1.

3. Physical Characteristics and Performance a. Holidays Coating shall be tested in accordance with AS 3894.2. Only pinhole-free coated test

piece shall be used in subsequent performance test. b. Hot Water Immersion

Test in accordance with AS 3862 at 600C ±21C for 100 days. The coating shall have a rating of equal to or greater than four when tested in accordance with method 408.2 of AS 1580, immediately after exposure.

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c. Water Absorption d. Flexibility When tested in accordance with AS 3682 at 00C, the coating shall not crack when

strained at 1.0% as calculated in the following equation : Strain β = 100 Sc % 2R – Sc where Sc Sample Thickness R Radius of Mandrel e. Impact Resistant When tested in accordance with ASTM G14 at 230C, the impact resistant shall be

equal to or greater than 2.0 J. The test may either be conducted on pipe with an outside diameter of 110mm to 125mm and wall thickness from 5mm to 7mm (6mm for flat plate). If cast plate is used, the side in contact with the anvil shall be machined flat prior to testing.

f. Abrasion Resistance The abrasion resistance test shall be undertaken according to ASTM D4060 with

CS18 wheel, 1000 cycles at 230C ± 21C. The weight loss shall be equal to or less than 40mg.

g. Cathodic Disbondment Coated test piece shall be tested according to sections 5, 6, 7, 8 and 9 of BS 3900 :

F 11. The coating when subjected to an impressed current at a negative voltage of 1.5V, shall not disbond more than 5mm radially from the end of the damaged coating after 28 days.

h. Cure Test This test applied only to thermosetting coatings, including liquid thermosets. After

an appropriate combination of time and conditions (both to be defined prior to the test by the manufacturer) from the point of coating application, thermosetting coating on coated test pieces shall be demonstrated to have been cured within

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declared limits. The method used shall also be declared. Whenever practicable, the method chosen should produce quantitative results.

Thermoplastic coating do not required this test. i. Adhesion Test Adhesion testing shall be carried out to determine the adhesive strength of the

coating to the substrate. It does not prove cohesive strength of the coating. Testing shall be by means of a ‘V’-cut test. Toughness of the film and visual evidence of coating in the anchor pattern valleys will give good indication of satisfactory adhesion.

The test shall be carried out using a sharp knife. Two cuts are made in the coating at

an included angle of approximately 300. Using the sharp point craft knife or similar, the knife shall be used to attempt to lift the point of ‘V’ in a single action levering against a fulcrum. Not more than 2mm of the ‘V’ shall be removed by this method by adhesive failure to the substrate or the adhesion shall be considered to be unsatisfactory.

The purchaser shall state his requirement for an adhesion test and the frequency of

testing at the time of enquiry and order. j. Salt Spray Test Prior to exposure, each test piece shall have a ‘V’ cut made through the coating in

accordance with D.3.10. Coated test pieces shall undergo 2100 hours exposure to salt spray in accordance with BS 3900 : F4. After exposure, the underfilm corrosion must not extend more than 1mm from the cut edge of the coating. There shall be no blistering in this area.

Addition, a ‘V’ cut test shall be carried out in accordance with D.3.10 on the

undamaged side of the sample after exposure. On this side, there shall be not more than 1mm disbondment, no underfilm corrosion and no blistering.

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j - ductile iron pillar hydrants

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