Appendix H

Appendix H — Acceptance testing

1. General

The Contractor is required to undertake acceptance testing of all pipelines constructed. Acceptance testing may be done progressively, but must be no earlier than 7 (seven) days after completion of the section to be tested. Two (2) days notice of acceptance testing should be given to Icon Water as Icon Water has the right to be present at any acceptance testing being performed. The results of all acceptance tests must be presented to Icon Water at the time of handover of the assets.

Pipes must be clean before any test is performed. If any of the tests prove to be unsatisfactory, detect and repair the fault and then re-test (in locating a fault it is appropriate to isolate the section under scrutiny where its position can then be detected through the use of appropriate methods). Continue to repair and re-test until a satisfactory result is obtained. Even if testing produces satisfactory test results, repair any pipeline or conduit in which there is a visible or detectable leak or blockage.

A visual inspection shall be carried out to ensure that all sewer lines present a full clean bore, except where curved sewers are specified on the drawings.

2. Air testing general

Air testing of gravity sewer pipes shall be by either pressure testing or vacuum testing. Air testing of maintenance holes shall be by vacuum testing, air testing of rising mains shall be by pressure testing only. Prior to tests commencing the Contractor shall nominate either vacuum or pressure testing, and shall not be permitted to change from one method to the other. The test shall include maintenance hole drops and house connection branches (service ties).

3. Pressure testing of sewers

The sewer to be tested shall be pressurised to the initial pressure specified in Table 2 for a minimum of 3 minutes to allow the temperature to stabilise.

The pressure shall then be dropped to the test start pressure specified in Table 2. Reaching this pressure marks the start of the test period.

The pressure shall then be observed for a period of 3 minutes for DN150 and DN225 sewers, or 5 minutes for DN300 sewers. If the pressure does NOT drop by more than 5 kPa during this observation period the sewer shall be deemed to have passed the test.

TABLE 2
Initial sewer pressurisation requirements for dry ground conditions


Depth to sewer invert

Initial pressure (kPa)

Test start pressure (kPa)

Less than 1.5 m

30

25

1.5 — 3.0 m

35

30

3.0 — 4.5 m

40

35

4.5 — 6.0 m

45

40

Deeper than 6.0 m

50

45

* In water charged ground, pressures are to be increased by 10 kPa for every metre height of water above the pipe invert.

4. Vacuum Ttesting of sewers

A vacuum of 28 kPa shall be drawn from the sewer to be tested. The valve shall then be closed, the pump turned off and the vacuum gauge monitored for 3 minutes. The sewer under test shall have passed the test if the vacuum does not fall by more than 5 kPa during the 3 minute period.

5. Vacuum testing of maintenance holes

After the maintenance holes have been constructed (including benching and fitting of convertor slab, surrounding frame and lid) they shall be tested as follows:

  • All backfilling shall be completed before testing commences;
  • The vacuum test head shall be placed on top of the maintenance hole and the seal inflated (initially with downward pressure being applied to the maintenance hole tester plate);
  • A vacuum of 33.5 kPa shall be drawn on the maintenance hole. The valve shall then be closed, the pump turned off and the time measured for the vacuum to fall to 30.0 kPa. The maintenance hole shall have passed the vacuum test if the time taken for this drop exceeds the time specified in Table 3.

TABLE 3
Maintenance hole vacuum test acceptance times for 3.5kPa vacuum drop


MH depth (m)

Time (seconds)

DN1050 MH

DN1200 MH

< 2.4

17

20

2.4 — 3

21

25

3 — 4

28

33

4 — 5

35

41

5 — 6

42

49

6 — 7

49

57

6. Ovality testing

All DN150 to DN300 PVC, PE and GRP gravity sewer pipes shall be tested with a proving tool to determine the presence of unacceptable deflections (ovality).

These tests shall be carried out AFTER all vacuum testing is complete and no sooner than 14 days after all the backfilling operations have been completed.

Testing shall involve pulling a proving tool, for the nominal size pipe shown in Table 4, through each section of pipe by hand winching to demonstrate that the maximum allowable deflection is not exceeded.

The proving tool shall comply with the following requirements:

  • Be of rigid steel or aluminium alloy fabrication;
  • Be non-adjustable;
  • Have an odd-number of legs (minimum 9);
  • Have an effective length of not less than its nominal diameter (DN);
  • Have pulling rings at each end;
  • The minimum size (DN) at any point along the length shall be as specified in Table 4;

    TABLE 4
    Proving tool size


    Nominal pipe size(DN)

    Minimum prover size (OD)

    PVC (Solid wall)

    PVC (Ultra–rib)

    GRP SN 10000

    150 142.6 145.8
    225 222.9 215.7
    300 280.8 289.2 315
  • Be permanently marked to indicate the nominated pipe size and material, the prover's outside diameter, the manufacturers name and a unique identification code;
  • Have been tested and passed for dimensional compliance by an independent, suitably accredited testing provider not more than 12 months prior to its use on any main that is to be handed over to Icon Water.

Sewer pipes that exhibit excessive ovality, by failing the maximum allowable deflection shown in Table 4 above, shall be replaced and the re-laid section re-tested for ovality.

Copies of the prover's test certificates shall be submitted to Icon Water upon request during the construction phase and at the handover inspection.

7. Closed circuit TV (CCTV) inspection

Icon Water requires a colour CCTV videotaped inspection of approximately 5% of the length of sewer mains to be submitted prior to accepting handover. Actual sewer mains to be surveyed will be nominated by Icon Water just prior to the handover inspection.

Such inspections must be:

  • Performed by an appropriately qualified CCTV operator;
  • Undertaken in accordance with the guidelines of the Australian Conduit Condition Evaluation Manual (Reference 5.3);
  • Of such quality that an accurate assessment of the internal condition of the sewer can be made.

The following items shall be provided:

  • One set of videotapes in VHS, PAL format covering all inspections. Cassettes shall be appropriately and clearly labelled. This labelling shall include the project description, location, the date of survey, and the survey agency and Developer involved;
  • One set of survey data from the data capture software. This is to be provided in Microsoft Excel format (or other read compatible) as per Coding Sheet Fig_1 on page 3 of the Australian Conduit Condition Evaluation Manual (Reference 5.3). Data is to be provided on 3.5 inch floppy disk media. Disks shall be appropriately and clearly labelled;
  • One hardcopy printout of survey data from the data capture software.

8. Water mains pressure tests

All water mains, including water services and stop cocks, shall be subjected to a hydrostatic field test pressure as follows:

  • For reticulation pipe work, unless a higher test pressure is specified on the Water Supply Master Plans, the equivalent of 140 metres head of water at the lowest point within the developed area of the zone;
  • For other pipe work, a test pressure as specified by Icon Water, but not less than the equivalent of 140 metres head of water at the lowest point of the newly constructed works.

It should be noted that the pressure test is intended to detect leakage at operating pressures which may actually be experienced during the life of the pipe work, not as a test of ultimate pressure capacity.

9. Pressure gauge certification

Pressure gauges used for water and sewer main acceptance testing must have current (that is, not older than 12 month) certification for accuracy from an independent, suitably accredited testing provider.

The gauges must be permanently marked to allow them to be identified against the test certificates.

Copies of the gauge certificates must be submitted to Icon Water upon request during the construction phase and at the handover inspection.

10. Product certification requirements

All products used in the construction of the water supply and sewerage systems being handed over to Icon Water shall meet the requirements of the relevant Australian Standards, and:

  • shall be certified as complying with the requirements of the Standards Australia Product Compliance Program (PCP). Such certification is demonstrated by complying products carrying a StandardsMark or WaterMark logo; and
  • shall have been appraised by WSAA and approved by Icon Water; or
  • shall have been approved by Icon Water.

Evidence of the manufacturer's product certification are to be submitted for Icon Water approval before ordering. Individual samples or an assembly may be required.

11. Test certificate requirements

The Developer is responsible for submitting to Icon Water signed and dated test data records resulting from scheduled inspections and tests. As a minimum these shall include the following items:

  1. Project Details: (Project Details common to all certificates)
    • Location, Section, Block/s;
    • Project Name, Consultant, Contractor;
    • Test Location, Date Testing Performed.
  2. Grading/Compaction Test Certificates (Bedding and Backfill Material):
    • Date of Sample, Type of Material;
    • Test Location, Compaction Test Depth, Grading Test Results.
  3. Pressure Test Certificates for Water:
    • Pipe Material — Type, Class, Manufacturer, Joint Type;
    • Initial Pressure, Test Pressure, Pressure Drop;
    • Pressure Gauge Certification Number, Pressure Gauge Certification Date.
  4. Pressure or Vacuum Test Certificates for Sewer:
    • Pipe Material — Type, Class, Manufacturer, Joint Type;
    • Pipe grade, Depth to IL, Internal Diameter (Solid Wall), Date of Completion of Backfill;
    • Initial Pressure or Vacuum, Test Pressure or Vacuum, Pressure or Vacuum Drop;
    • Pressure/Vacuum Gauge Certification Number, Pressure/Vacuum Gauge Certification Date.
  5. Ovality Test Certificates:
    • Pipe Material — Type, Class, Manufacturer, Joint Type;
    • Pipe Grade, Depth to IL, Internal Diameter (Solid Wall), Date of Completion of Backfill;
    • Prover Size, Prover Identification Number, Prover Certification Details (number and date).
  6. Vacuum Test Certificates for Maintenance Holes:
    • MH number (as per drwg), MH depth;
    • Initial Vacuum Reading, Test Vacuum Reading, Duration of Test;
    • Vacuum Gauge Certification Number, Vacuum Gauge Certification Date.
  7. CCTV Inspection:
    • Refer to Clause 7 above for CCTV inspection requirements.