Iplex Pipelines (Australia) Pty Ltd · Millennium PE pipe_Peer Review final.docx Peer Reviewers ... e.g. PE 80 and PE 100, were introduced with greater resistance to both stress cracking

WSAA Product Appraisal Report No PA 1610 1

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Iplex Pipelines (Australia) Pty Ltd PRODUCT APPRAISAL REPORT 1610

Iplex Pipelines Millennium® High Stress Crack Resistant Polyethylene Pipe

AS/NZS 4130:2009 Polyethylene (PE) pipes for pressure applications and PIPA POP016 High Stress Crack Resistant PE 100

Publication Date 10 October 2016


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Document History

The following information indicates the changes made to this document.

Date Version File Location

10/8/2016 Client Draft

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2016\PA 1610 Iplex Pipelines Millennium PE Pipe\PA 1610 Iplex Millennium PE pipe_Client Peer Review Draft.docx

10/8/2016 Peer Review

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2016\PA 1610 Iplex Pipelines Millennium PE Pipe\PA 1610 Iplex Millennium PE pipe_Client Peer Review Draft.docx

10/10/2016 Publication

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2016\PA 1610 Iplex Pipelines Millennium PE Pipe\PA 1610 Iplex Millennium PE pipe_Peer Review final.docx

Peer Reviewers

Name/Title Organisation Date

WSAA Product Appraisal Technical Advisory Group WSAA 5/9/2016

Expert Panel WSAA 5/9/2016

Carl Radford, Product Appraisal Manager WSAA 10/10/2016

Approvals

Name/Title Signature Date

Carl Radford, Product Appraisal Manager Carl Radford 10/10/2016


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Overview of WSAA

The Water Services Association of Australia (WSAA) is the peak industry body that supports the Australian Urban Water Industry. Its members and associate members provide water and sewerage services to approximately 20 million Australians and many of Australia’s largest industrial and commercial enterprises.

The Association facilitates collaboration, knowledge sharing, networking and cooperation within the urban water industry. It is proud of the collegiate attitude of its members which has led to industry-wide approaches to national water issues.

WSAA can demonstrate success in the standardisation of industry performance monitoring and benchmarking, as well as many research outcomes of national significance. The WSAA Executive retains strong links with policy makers and legislative bodies and their influences, to monitor emerging issues of importance to the urban water industry. WSAA is regularly consulted and its advice sought by decision makers when developing strategic directions for the water industry.

WSAA was formed in 1995 as a non-profit organisation to foster the exchange of information relating to the provision of urban water services between industry, government and the community, and to promote sustainable water resource management.

The Association’s main activities focus on four areas:

1. Influencing national and state policies on the provision of urban water services and sustainable water resource management;

2. Promoting debate on environmentally sustainable development and management of water resources and the community health requirements of public water supplies;

3. Improving industry performance and establishing benchmarks and industry leading practices for water service processes; and

4. Fostering the exchange of information on education, training, research, water and wastewater management and treatment and other matters of common interest .

Copyright

This document is copyrighted. Apart from any use as permitted under the Copyright Act 1968, no part of this document may be reproduced or transmitted in any form or by any means, electronically or mechanical, for any purpose, without the express written permission of Water Services Association of Australia Limited.

© Copyright 2016 by WATER SERVICES ASSOCIATION of Australia Limited All rights reserved.


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CONTENTS

1 EXECUTIVE SUMMARY ............................................................................................................................................. 5

1.1 Recommendations ................................................................................................................................................ 5

2 THE APPLICANT ......................................................................................................................................................... 6

2.1 The Supplier .......................................................................................................................................................... 6

2.2 The Manufacturer .................................................................................................................................................. 6

3 THE PRODUCT ........................................................................................................................................................... 6

4 SCOPE OF THE APPRAISAL ..................................................................................................................................... 9

5 APPRAISAL CRITERIA ............................................................................................................................................... 9

5.1 Quality Assurance Requirements .......................................................................................................................... 9

5.2 Performance Requirements................................................................................................................................... 9

6 COMPLIANCE WITH APPRAISAL CRITERIA............................................................................................................. 9

6.1 Compliance with Quality Assurance Requirements ............................................................................................... 9

6.2 Compliance with Performance Requirements ..................................................................................................... 10

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION ................................................................................... 12

8 PRODUCT MARKING ............................................................................................................................................... 12

9 PACKAGING AND TRANSPORTATION ................................................................................................................... 13

10 PRODUCT WARRANTY .......................................................................................................................................... 13

11 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT ..................................... 13

12 OUTCOMES OF EXPERT PANEL PRODUCT REVIEW......................................................................................... 13

13 FUTURE WORK ...................................................................................................................................................... 13

14 LIFE EXPECTANCY ................................................................................................................................................ 13

15 FUTURE WORKS ......................................................................................... ERROR! BOOKMARK NOT DEFINED.

16 DISCLAIMER ........................................................................................................................................................... 14

16.1 Issue of Report .................................................................................................................................................. 14

16.2 Limits on Reliance on Information and Recommendations................................................................................ 14

16.2.1 Disclaimer of liability ................................................................................................................................... 14

16.2.2 Intellectual Property and other rights .......................................................................................................... 14

16.2.3 Need for independent assessment ............................................................................................................. 15

16.3 No Updating ...................................................................................................................................................... 15

16.4 No Warranty ...................................................................................................................................................... 15

APPENDIX A - QUALITY CERTIFICATIONS ............................................................................................................... 16

APPENDIX B - WSA PRODUCT SPECIFICATION ...................................................................................................... 30

APPENDIX C - SUPPLIER CONTACTS ....................................................................................................................... 31

APPENDIX D – IPLEX MILLENNIUM® PIPE ................................................................................................................ 32


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1 EXECUTIVE SUMMARY

Iplex Pipelines is a long established Australian pipe and fitting manufacturing company. The Iplex product range includes polyethylene pipes that were originally made using a first generation material known as PE Type 50. Progressively more advanced PE compounds, e.g. PE 80 and PE 100, were introduced with greater resistance to both stress cracking and rapid crack propagation. In subsequent years there have been incremental improvements in the performance of PE pipe compounds and the Australian/New Zealand Standards for both PE compounds and pipes have been progressively updated to reflect the enhanced characteristics.

More recently Qenos has developed a new PE 100 compound having greatly increased resistance to stress cracking compared to normal PE 100. Iplex will be utilising this material in its range of Millennium® pipes. The new compound, Alkadyne® HCR193B, complies with all of the requirements of PE 100 as defined in AS/NZS 4131 and additionally meets the stress crack resistance requirements defined in PIPA POP016 for PE 100 HSCR. These additional requirements include a minimum duration of 5,000 hours in the 80°C Notched Pipe Test compared to the 500 hours for normal PE 100. Additional tests verifying the enhanced stress crack resistance include the full-notch creep test, Two-Notch Creep Test and the Point Load Test. Each of these tests is internationally recognised and their use in differentiating between normal PE 100 and PE 100 HSRC is widely acknowledged. In 2009 the German Standards organisation DIN published a Publicly Available Specification (PAS 1075) defining the HSCR performance requirements. In DIN PAS 1075 it is stated compliant PE piping possesses fundamentally higher resistance to slow crack growth in comparison with (normal) PE 100 piping. The PE 100 HSCR specification provided in PIPA POP016 borrows from DIN PAS 1075 but takes into account developments that have occurred since 2009. Both the PAS and POP016 contain tests developed especially to assess HSCR materials in a reasonable time frame.

Millennium® pipes share exactly the pressure resistance capability of normal PE 100 as defined in AS/NZS 4130 together with the same welding, weathering and handling characteristics. The difference between Iplex’s Millennium® pipe and normal PE 100 is the use of PE 100 HSCR compound. The new compound increases the ability of the pipe to withstand the effects of damage to the external surface from handling and installation or the impingement of point loads during service. It will also increase the ability of the pipes to withstand damage that might result from third party interference or squeeze-off.

By convention, allowance is made for external pipe damage to PE pipes up to 10% of the wall thickness. However, the relationship between the effect of damage and percentage depth of damage is not necessarily independent of wall thickness. The stress intensity factor at the tip of a 10% scratch in a DN 500 SDR11 pipe will be significantly higher than at the tip of a 10% scratch in a DN 110 SDR11 pipe operating at the same pressure. PE 100 HSCR would provide greater assurance, particularly with thicker walled pipes, pipes that might incur more extensive surface damage or pipes subjected to unintended point loads.

Millennium® pipe represents a significant enhancement in the stress crack resistance of PE 100 and makes the product more tolerant of damage. There may be circumstances where a thicker walled PE 100 pipe would need to be specified because of expected surface damage whilst a PE 100 HSCR pipe could be specified on the basis of pressure rating alone. That is, in some situations Millennium® pipe might obviate the need for a thicker wall, which in turn would improve the hydraulics of the pipeline.

The production of Millennium® pipe is covered by appropriately certified quality management systems and product certifications.

1.1 Recommendations

It is recommended that WSAA members, subject to any specific requirements of the member, accept or authorise the Iplex Pipelines (Australia) Pty Limited Millennium® high stress crack resistant PE 100 pipe ("Product") as detailed in this report for use in pressure applications


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including water supply and sewerage provided the design, installation, acceptance testing and operation are in accordance with the appropriate WSAA Codes, including WSAA member integrated Codes, nominated Australian Standards and manufacturer’s requirements.

2 THE APPLICANT

Iplex Pipelines (Australia) Pty Limited ABN 56 079 613 308.

2.1 The Supplier

Iplex Pipelines (Australia) Pty Limited.

2.2 The Manufacturer

Iplex Pipelines Australia Pty Limited is a wholly owned business unit of the Australian Stock Exchange listed company Fletcher Building Limited. The company has operations in every Australian state. Iplex manufactures and supplies plastics and metallic pipe and conduit for applications including plumbing, irrigation, mining, industrial and chemical processes, electrical, telecommunications, gas, stormwater, sewer, raw, recycled and drinking water. Products manufactured to Australian Standards include PVC-U pipes and fittings for stormwater, rainwater, DWV, pressure and electrical applications; ApolloBlue™ PVC-O, Rhino® PVC-M; BlackMax™ and SewerMax™ PP pipes; POLIplex® PE pipes; K2™ PE-X and Pro-fit® PB plumbing systems and K1™ MLP consumer gas piping. The company also supplies a range of DI pipes and fittings, SS clamps and off-takes, valves and tapping bands. Additionally, Iplex is the Australian distributor of Flowtite™ GRP pipes manufactured in South Australia. Iplex is the only Australasian manufacturer of AS/NZS 4130 polyethylene pressure pipe and fittings in sizes as large as DN 2000.

Iplex’s Australian manufacturing plants are strategically located close to major development and population regions in Innisfail, Townsville, Brisbane, Toowoomba, Sydney, Albury, Adelaide and Perth.

Iplex Pipelines is an Australian pioneer in plastics pipe and fittings production with more than 50 years’ experience. The company commenced operations in Adelaide in 1962 as Iplex Plastics and has variously operated as Hardie Iplex Plastics, James Hardie Pipelines and now Iplex Pipelines. Iplex Pipelines is a foundation member of the Plastics Industry Pipes Association of Australia (PIPA) and was an active member of earlier industry organisations including AusPoly.

As part of its ongoing commitment to the development of Standards for plastics pipe and fittings, Iplex personnel serve on Standards Australia and PIPA technical committees and Australian Pipelines and Gas Association (APGA) working groups. The company also participates in ISO activities related to plastics pipes and fittings product and testing Standards. In addition to WaterMark®, StandardsMark™ and ApprovalMark™ third-party product certification, all operations are conducted under a quality management system, certified to ISO 9001 by SAI Global, (Licence QEC 0037) or by ApprovalMark (Licence AMI-QM 78003).

To support the application of its extensive product range, Iplex employs professional engineers to assist users, clients, designers and asset owners with appropriate product selection and pipeline design. Iplex publishes comprehensive engineering design guides that are available for download via its website. The Iplex PocketENGINEER® is a web portal where following registration, users can freely access design software to simplify mechanical, hydraulic, civil and chemical resistance aspects of pipeline design.

3 THE PRODUCT

Iplex Pipelines (Australia) Pty Limited Millennium® HSCR PE100 pipe is product certified by SAI Global (Thurgoona) and ApprovalMark (Wellcamp) and available in diameters from DN 16 to DN 1200 and pressure classes as shown in the table that follows on page 8. Millennium® pipe is manufactured to AS/NZS 4130, the same Standard as applicable to


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normal PE 100. However, in addition the product is made specifically from Alkadyne® HCR193B compound which has greatly enhanced stress crack resistant properties as described in PIPA POP016. That is, Millennium® pipe is the same as normal PE 100 pipe in all respects such a dimensions, mass, handling, pressure rating and welding except it has a much greater resistance to stress cracking. This is particularly significant because whilst PE pipes are designed on the basis of the relationship between hoop stress and time to ductile failure, in practice the service life is often determined by the time to brittle fracture. A substantial increase in the resistance to stress cracking will make the product more tolerant of surface damage and point loads and may in some circumstances, for example directionally drilled pipelines or burst-pipe rehabilitation applications, result if a higher SDR (thinner wall) being used for a particular application. This can result in lower material costs and improved hydraulics. The PE compound Alkadyne® HCR193B with its inherent improvements in stress crack resistance is therefore an essential feature of Millennium® pipe.

Alkadyne® HCR193BX is produced with same manufacturing technology as “standard” Qenos PE 100 grade HDF193B but with the molecular architecture modified to specifically enhance stress crack resistance. The properties of HCR193BX resin important to heat fusion process are very similar to those of HDF193B. In particular the melting and cooling characteristics as well as rheological performance at low shear rate, which are conditions encountered during heat fusion process such as butt welding (BW) and electrofusion (EF) joining are similar to the Qenos PE100 Alkadyne® HDF193B. Therefore, HCR193BX pipes will form a quality joint in butt welding including pipes of large diameter with thick walls and electrofusion processes with either couplers or tapping saddles.

HCR193B has undergone the full qualification testing process for compliance to PE 100 specifications (AS/NZS 4131) and to PE 100 HSCR specifications (POP016) including testing of pipes with identification stripes – blue for water and beige for sewer. The qualification process ensured that the total structure has been tested and compliance to the specifications fully demonstrated. The HSCR qualification process was robust and included testing of pipes up to very large diameters and wall thickness up to 90 mm.

The HSCR characteristics of HCR193B have been demonstrated in accordance with POP016 which includes four tests that have been either modified to increase the severity or developed explicitly to characterise compounds with exceptional stress crack resistance. For example, the Notched Pipe Test specified in AS/NZS 4130 and AS/NZS 4131 nominates a test duration of ≥ 500 hours for normal PE 100. HSCR materials are required to exceed 5,000 hours. It is noted that when the Notched Pipe Test was originally introduced for earlier generations of PE, the requirement was only 165 hours. Whilst not a requirement of the specification it was shown that even when the notch depth for the test piece was increased from the specified 20% of the pipe wall thickness to 30%, Millennium® pipe made with HCR1993B still exceeded the performance required of PE 100.

The other tests used to qualify HSCR compounds are also internationally recognised. These are the Full Notch Creep Test (ISO 16770), Two Notch Creep Test (EN 12814-3) and Point Load Test (DIN PAS 1075). According to DIN PAS 1075, the polyethylene piping described possesses “fundamentally” higher slow crack growth resistance properties in comparison with PE 80 and PE 100 piping.

Millennium® pipe is available in black and black with blue, purple or beige stripes or coextruded jackets. Natural compound is available for compounding the colours so the stripe and jacket compounds are made with the same high stress crack resistance as the parent pipe, which may be important to protect against crack growth initiating from external surface damage. All striping and jacket compounds are made in accordance with the requirements of AS/NZS 4130.

Millennium® pipe is available in straight lengths or coils on the same basis as standard POLIplex PE 100 pipes.


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4 SCOPE OF THE APPRAISAL

This product appraisal applies to Iplex Pipelines (Australia) Pty Limited Millennium® HSCR pipe complying with AS/NZS 4130 and utilising High Stress Crack Resistant (HSCR) pre-compounded PE 100 as defined in PIPA Industry Guideline POP016 High Stress Crack Resistant PE 100. Millennium® pipe is available in diameters DN 16 to DN 1200 as described in Table 2 of AS/NZS 4130 and the table of pipe sizes detailed on page 8. The compound used in the extrusion of Millennium pipe is a PE100 HSCR material Alkadyne® HCR193B produced by Qenos Pty Ltd at its Altona factory in Victoria.

Millennium® pipe will be produced at Iplex’s Thurgoona (NSW) and Wellcamp (Qld) factories.

For water industry applications Millennium® pipe can be supplied as all-black or black with blue, purple or beige stripes or jackets.

Standard straight lengths and coil lengths are supplied in accordance with the product schedule. Note that with respect to diameters, SDR, pressure rating and supplied lengths, Millennium® pipe is the same as traditional POLIplex® PE 100.

5 APPRAISAL CRITERIA

5.1 Quality Assurance Requirements

The WSAA Product Appraisal Technical Advisory Group accepts PE 100 pipes manufactured in compliance with AS/NZS 4130 and duly certified by means of an ISO Type 5 product certification scheme undertaken by a JAS-ANZ accredited Certification Assessment Body (CAB) or by an international accreditation system recognised by JAS-ANZ.

The manufacturer is generally expected to have a production management and control system that has been duly accredited in accordance with AS/NZS ISO 9001 as a prerequisite to undergoing a product certification audit.

5.2 Performance Requirements

Iplex Pipelines (Australia) Pty Limited Millennium® HSCR PE 100 pipe has been appraised for compliance with AS/NZS 4130 and POP016. It is a requirement of AS/NZS 4130 that the compound used has in turn been demonstrated to comply with the performance requirements of AS/NZS 4131.

Appraisal criteria are also determined by the WSAA Product Appraisal Technical Advisory Group and regularly reviewed to ensure that the criteria reflect the requirements of WSAA members.

The following Product Specification is also relevant to this application:

WSA PS-207 Polyethylene (PE) Pipes for Pressure Applications – Water Supply and Sewerage.

A copy of the above Product Specification can be found in Appendix B or downloaded from the WSAA website.

6 COMPLIANCE WITH APPRAISAL CRITERIA

6.1 Compliance with Quality Assurance Requirements

Iplex Pipelines (Australia) Pty Limited products are manufactured under a Quality Management System certified as fulfilling the requirements of ISO 9001, Certificate Registration Number QEC0037, issued in Australia by SAI Global for manufacturing sites including Thurgoona. SAI Global is accredited by JAS-ANZ. This certificate was issued on 9th February 2015 and is currently valid until 9th January 2018. Product manufactured at Wellcamp, Qld are also produced under the Quality Management System certified as fulfilling the requirements of ISO 9001, Certificate Registration Number AMI-QM 78003, issued in Australia by ApprovalMark International. ApprovalMark is accredited by JAS-ANZ. The certificate was issued on 15 th December 2015 and is currently valid until 15 December 2017.


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Iplex Pipelines (Australia) Pty quality management system addresses the design, manufacture where appropriate, purchasing, warehousing and distribution and sale of: extruded PE, PB, PVC, glass reinforced plastics and macrocomposite pipes, PVC profiles; PE, PVC and GRP fabricated fittings; PVC and PP moulded fittings and PP extruded pipe and stainless steel repair couplings. The purchase and distribution of complementary products is also covered. The above products are suitable for applications such as pressure, sewerage, drainage, stormwater, gas, electrical, rural, construction and communication ”.

6.2 Compliance with Performance Requirements

Millennium® pipe is required to be manufactured from compound complying with AS/NZS 4131, satisfy the performance requirements of PE 100 as stated in AS/NZS 4130 and the additional stress crack resistance tests listed in POP016.

Qenos has submitted reports confirming Alkadyne® HCR193B compound meets all the requirements of AS/NZS 4131 as follows in Table 1 below and the product has been third-party certified as compliant by SAI Global, StandardsMark Licence PST20138:

TABLE 1 TYPE TESTING ALKADYNE® HCR193B COMPOUND TO AS/NZS 4131

Attribute Clause Requirement Testing

Authority

Report

Number

Result

MFR 4.1.2 Not vary by >30% from nominated value (0.019 g/10min.)

Qenos NATA 20120133-1A 0.19 Complies

Density 4.1.3 Not deviate from nominated value (0.959) by more than 0.003 g/cm3.

Qenos NATA 20120133-1D 0.9592 Complies

Thermal Stability

4.2.1 ≥40 minutes at 200°C.

Qenos NATA 20120245-1E 46.5 minutes at 210°C.

Complies

Carbon black content

4.2.2 2.25±0.25% Qenos NATA 20120245-1G 2.17%

Complies

Carbon Black average particle size and maximum toluene extract

10 – 25 nm

≤0.10%

Qenos material specification

Complies

Dispersion 4.3.5 Av. Max ≤60μm Qenos NATA 20120245-1F Grade 2.5, Appearance A3.

Complies.

Volatile content

5 ≤350 mg/kg Qenos NATA 20120245-1H 191 mg/kg Complies

Classification 6 σLPL ≥ 10MPa at 50 y and 20°C.

Qenos NATA 20120133-1C σLPL 10.23

Complies

Rapid crack propagation

6.2 Crit. Press. ≥1.0 MPa at 0°C.

Becetel 11776 Crack arrest at 1.0 MPa at 0°C. Complies


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Attribute Clause Requirement Testing

Authority

Report

Number

Result

Resistance to Internal pressure

7 >165 h at 80°C and 5.4 MPa hoop stress

Qenos NATA 20120133-1 >276.2 h

Complies

Slow crack growth resistance

8 > 500 h at 80°C and 920 kPa

Qenos NATA 20120133-3 Triplicate samples all >6910 h

Complies

Effect on water

10 Satisfy AS/NZS 4020

AWQC 125252 Complies

Qenos submitted the test reports to PIPA and the material is now listed in Industry Guideline POP004 as PE 100 compliant. In addition, further analysis of the results obtained by testing to ISO 9080 to establish the material classification, demonstrates HCR 193B also satisfies the temperature rerating factors in PIPA Industry Guideline POP013, Table 2. Therefore, the temperature rerating factors applicable to PE 100 are equally applicable to Millennium® pipe.

Qenos has submitted formal test reports confirming HCR193B compound meets all the requirements of POP016 and can therefore be classified as a High Stress Crack Resistant material. Refer to Table 2.

TABLE 2 PIPA POP016 PE100 HSCR COMPOUND PERFORMANCE TESTS

Test Method/Standard Requirement Report Result

Notched Pipe Test (NPT)

ISO 13479 > 5000 h at 80°C and 920 kPa

Qenos NATA 20120133-3

8436.8 h

6910.8 h

9821.1h Complies

Full Notch Creep Test (FNCT)

ISO 16770 > 8,760 h at 80°C KIWA

LC 10969/1 (6)

All >8,900h Complies

Two Notch Creep Test (2NCT)

EN 12814.3 >3,300 h KIWA

LC 10969/3 (6)

LC 10969/4 (6)

LC 10969/5 (3)

All > 3400 h Complies

Point Load Test (PLT)

DIN PAS 1075 > 8,760 h at 80°C (or by correlated accelerated test > 450 h at 90°C)

Hessel Ingenieurtechnik R16 01 2780-(PLT+) (Triplicate)

All > 1316 h. Complies

Having demonstrated compliance of the compound with AS/NZS 4131 and POP016, the third requirement for Millennium® pipe is compliance with AS/NZS 4130.

Millennium® pipe is manufactured from Alkadyne HCR193B that complies with AS/NZS 4131 and therefore immediately satisfies the AS/NZS 4130 requirements for composition and effect on water and the POP016 requirements for slow crack growth by Notched Pipe Pressure Test, Full Notch Creep Test, Two Notch Creep Test and Point Load Test.


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Testing of Millennium® pipes, including batch release tests are performed in accordance with the product certification schedules for Wellcamp (ApprovalMark WaterMark Certificate of Conformity – Level 1 Certificate Number WM 72306 Expires 10 February 2018) and for Thurgoona (SAI Global StandardsMark Certificate Number SMKP20088 Expires 5 May 2019).

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION

Polyethylene pipes have been commonly used in the Australian water industry for many years. In terms of handling, installation and operation, Millennium® pipe is the same as the normal PE100. No additional training is required explicitly for Millennium® pipe.

Both butt welding and electrofusion welding equipment and conditions are the same as for normal PE 100 and reference can be made to, for example, the PIPA website for details of training organisations.

References relevant to the transporting, handling and installation of Millennium® pipes include:

Millennium® Technical Brochure available at www.iplex.com.au website.

POLIplex® PE pipe and fittings systems Product Technical Library at www.iplex.com.au website.

Alkadyne® HCR193B Technical Guide available from Qenos.

AS/NZS 2033 Installation of polyethylene pipe systems.

AS/NZS 2566.1 Buried flexible pipelines Part 1: Structural design.

AS/NZS 2566.2 Buried flexible pipelines Part 2: Installation.

WSA PS-207 Polyethylene (PE) Pipes for Pressure Applications – Water Supply and Sewerage.

WSA PS-327 Tapping Bands, Mechanical, for use with Polyethylene (PE) Mains for Pressure Applications – Water Supply.

WSA PS-329 Tapping Saddles. Electrofusion, for use with Polyethylene (PE) Mains for Pressure Applications – Water Supply and Pressure Sewerage.

PIPA POP001 Electrofusion Jointing of PE Pipe and Fittings for Pressure Applications

PIPA POP003 Butt Fusion Jointing of PE Pipes and Fittings - Recommended Parameters

PIPA POP005 Packaging, Handling and Storage of Polyethylene Pipes and Fittings

PIPA POP010A Polyethylene Pressure Pipes – Design for Dynamic Stresses.

PIPA POP013 Temperature Rerating of PE Pipes

PIPA POP014 Assessment of Polyethylene Welds

PIPA POP202 PVC and PE Pipe Installation On Curved Alignments.

PIPA POP201 Resistance of Plastics Pipes and Fittings to Water and Wastewater Chemicals.

8 PRODUCT MARKING

All Iplex Pipelines products including Millennium® pipe are marked in accordance with the requirements of the appropriate standards, e.g. Millennium® pipes are marked in accordance with AS/NZS 4130:2009 as per the following:

• Manufacturers Name: IPLEX PIPELINES

• Product Name: MILLENNIUM®

• Product Code as appropriate

http://www.iplex.com.au/



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• Pipe Series Number: S1

• Pipe Material: HSCR PE100

• Nominal outside diameter and SDR: e.g. DN 110 SDR11

• Nominal Pressure: e.g. PN 16

• Date of manufacture using the ISO system: e.g.160401 (i.e. 1st April 2016)

• The time of manufacture

• Identification of manufacture site and production line: e.g. 3A01 for extrusion line 1 Albury (Thurgoona) and 4T03 for extrusion line 3 Toowoomba (Wellcamp)

• The standard number: AS/NZS 4130

• Standards Mark symbol (I>>>>>I) or WaterMark (symbol: W) as appropriate.

• Licence Number: SMK20088 or WM72306 as appropriate.

• Special Application information: e.g. RECYCLED WATER – DO NOT DRINK or PUMP SEWAGE – DO NOT DRINK as appropriate.

Example

{Product code} IPLEX PIPELINES MILLENNIUM® S1 DN1200 PN12.5 SDR13.6 PE 100 HSCR {yymmdd} {hh} {CODEX} AS/NZS 4130 {Type 5 Certification} {WaterMark} {Licence no:}

9 PACKAGING AND TRANSPORTATION

Packaging and transport of Millennium® HSCR PE 100 pipe is the same as has been traditionally used for normal PE 100 including Iplex’s POLIplex products. The product is available in straight lengths or coils depending upon the pipe diameter. Additional information on transportation, storage and handling is available in AS/NZS 2033 Installation of polyethylene pipe systems, PIPA POP005 Packaging, Handling and Storage of Polyethylene Pipes and Fittings and PIPA TN002 Weathering of PE pipes.

10 PRODUCT WARRANTY

The products are covered by the normal commercial and legal requirements of the Competition and Consumer Act 2010 (Cth), which covers manufacture to the relevant standard, and details of Iplex Pipelines (Australia) Pty Limited warranty is included in their terms and conditions of sale and is available from the Iplex website (www.iplex.com.au).

11 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING

REPORT

Polyethylene pipe has been utilised by Australian Water Agencies for many years. It is considered unnecessary to request further field trials for the purpose of this Appraisal.

12 OUTCOMES OF EXPERT PANEL PRODUCT REVIEW

There are no outstanding issues following the expert panel review.

13 FUTURE WORK

No future works have been identified in this Appraisal.

14 LIFE EXPECTANCY

Based on the documented conformance with the designated Standards and specifications Millennium® pipe will outperform normal PE 100.

Plastics pipe systems are often designed on the basis of 50 year extrapolated test data. This is established international practice but is not intended to imply the service life of Millennium® HSCR PE 100 pipe is limited to 50 years. For correctly manufactured and installed systems,



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the actual life cannot be predicted, but can logically be expected to be well in excess of 100 years before major rehabilitation is required.

Using modern rehabilitation techniques, pipeline systems can be successfully maintained and operated indefinitely provided the pipe and other structures do not collapse.

15 DISCLAIMER

This Product Appraisal Report (Report) is issued by the Water Services Association of Australia Limited on the understanding that:

This Report applies to the product(s) as submitted. Any changes to the product(s) either minor or major shall void this Report.

To maintain the recommendations of this Report any such changes shall be detailed and notified to the Product Appraisal Manager for consideration and review of the Report and appropriate action. Appraisals and their recommendations will be the subject of continuous review dependent upon the satisfactory performance of products.

WSAA reserves the right to undertake random audits of product manufacture and installation. Where products fail to maintain appraised performance requirements the appraisal and its recommendations may be modified and reissued. Appraisal reports will be reviewed and reissued at regular intervals not exceeding five (5) years.

The following information explains a number of very important limits on your ability to rely on the information in this Report. Please read it carefully and take it into account when considering the contents of this Report.

Any enquiries regarding this report should be directed to the Program Manager, Carl Radford, Phone: 03 8605 7601 email [email protected].

15.1 Issue of Report

This Report has been published and/or prepared by the Water Services Association of Australia Limited and nominated Project Manager and peer group of technical specialists (the Publishers).

The Report has been prepared for use within Australia only by technical specialists that have expertise in the function of products such as those appraised in the Report (the Recipients).

By accepting this Report, the Recipient acknowledges and represents to the Publisher(s) and each person involved in the preparation of the Report that the Recipient has understood and accepted the terms of this Disclaimer.

15.2 Limits on Reliance on Information and Recommendations

15.2.1 Disclaimer of liability

Neither the Publisher(s) nor any person involved in the preparation of the Report accept(s) any liability for any loss or damage suffered by any person however caused (including negligence or the omission by any person to do anything) relating in any way to the Report or the product appraisal criteria underlying it. This includes (without limitation) any liability for any recommendation or information in the Report or any errors or omissions.

15.2.2 Intellectual Property and other rights

The Water Services Association of Australia Limited does not undertake any assessment of whether the importation, manufacture, sale or use of the Product the subject of this Report infringes the intellectual property rights or proprietary rights of any person. Recipients of the report should undertake their own assessment of whether (as relevant) the importation, manufacture, sale or use of the relevant Products infringe the intellectual property rights or other proprietary rights of any person. If the Product infringes intellectual property rights or other proprietary rights there is potential for the supply of the Products to be interrupted.

mailto:[email protected]


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From time to time the Water Services Association of Australia Limited and the other Publishers may receive notice of allegations that the importation, manufacture, sale or use of the Product infringes intellectual property rights or other proprietary rights. The Water Services Association of Australia Limited's policy is to not refer to such allegations in its reports or take any other steps to put Recipients on notice of such allegations, unless and until it is aware that the allegations have been admitted or proved in Court. As such, Recipients acknowledge, agree and accept that the Water Services Association of Australia Limited may have information in its possession about intellectual property rights infringement allegations or other infringement allegations in relation to the Product which are not referred to or disclosed in this Report and which are not otherwise communicated to Recipients.

15.2.3 Need for independent assessment

The information and any recommendation contained (expressly or by implication) in this Report are provided in good faith (and subject to the limitations noted in this Report).. However, you should treat the information as indicative only. You should not rely on that information or any such recommendation except to the extent that you reach an agreement to the contrary with the Publisher(s).

This Report does not contain all information that a person might require for the purposes of assessing any product discussed or appraised within it. The product appraisal criteria used in preparing this Report may not address all relevant aspects of the Product.

Recipients should seek independent evidence of any matter which is material to their decisions in connection with an assessment of the Product and consult their own advisers for any technical information required. Any decision to use the Product should take into account the reliability of that independent evidence obtained by the Recipient regarding the Product.

Recipients should also independently verify and assess the appropriateness of any recommendation in the Report, especially given that any recommendation will not take into account a Recipient’s particular needs or circumstances.

WSAA has not evaluated the extent of the product liability and professional indemnify insurance that the provider of the product maintains. Recipients should ensure that they evaluate the allocation of liability for product defects and any professional advice obtained in relation to the product or its specification including the requirements for product liability and professional indemnity insurance.

15.3 No Updating

Neither the Publisher(s) nor any person involved in the preparation of this Report [has] [have] any obligation to notify you of any change in the information contained in this Report or of any new information concerning the Publisher(s) or the Product or any other matter.

15.4 No Warranty

The Publisher(s) do[es] not, in any way, warrant that steps have been taken to verify or audit the accuracy or completeness of the information in this Report, or the accuracy, completeness or reasonableness of any recommendation in this Report.


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APPENDIX A - QUALITY CERTIFICATIONS

Copies of the following Quality Certification Certificates are available for downloading from the WSAA ‘Members Only’ IPAM Portal Website.

TABLE A1 IPLEX PIPELINES (AUSTRALIA) PTY LIMITED– MANAGEMENT SYSTEMS

Applicant’s Business: Corporate Office. Level 4, 68 Waterloo Road, Macquarie Park, NSW 2113

This certification applies to operations at Strathpine Qld, Thurgoona, NSW, Chipping Norton NSW,

Bohle Qld, Elizabeth SA and Reservoir Vic.

(Attach all QA system certificates in full including schedules and last audit report)

Quality Systems Standard AS/NZS ISO9001:2008

Certification licence no. QEC0037

Certifying agency SAI Global

First date of certification 3 April 1990

Current date of certification 9 February 2015

Expiry date of certification 9 February 2018

TABLE A2 IPLEX PIPELINES (AUSTRALIA) PTY LIMITED – MANAGEMENT SYSTEMS

This certification applies to operations at Osborne Park WA and Toowoomba Qld.


Quality Systems Standard AS/NZS ISO9001:2008

Certification licence no. AMI-QM 78003

Certifying agency ApprovalMark International

First date of certification 15 December 2014

Current date of certification 15 December 2014

Expiry date of certification 15 December 2017

TABLE A3 IPLEX PIPELINES (AUSTRALIA) PTY LIMITED – PRODUCT

CERTIFICATION (STANDARDSMARK)

Applicant’ s Business: 31 Terry Court Thurgoona NSW


Product Standard/Spec. AS/NZS 4130 – Polyethylene (PE) pipes for pressure applications

Certification licence StandardsMark Licence SMK 20088

Issuing certification body SAI Global

First date of certification 7 May 1999

Current date of certification 21 January 2015

Expiry date of certification 5 May 2019


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TABLE A4 IPLEX PIPELINES (AUSTRALIA) PTY LIMITED – PRODUCT

CERTIFICATION (APPROVALMARK)

Applicant’ s Business: Lot 1 Witmack Road, Wellcamp QLD 4350


Product Standard/Spec. AS/NZS 4130 – Polyethylene (PE) pipes for pressure applications

Certification licence WM 72306

Issuing certification body ApprovalMark International

First date of certification 10 February 2013

Current date of certification 10 February 2013

Expiry date of certification 10 February 2018

TABLE A5 QENOS PTY LIMITED – PRODUCT CERTIFICATION (STANDARDSMARK)

Applicant’ s Business: 471 Kororoit Creek Road, Altona, Vic 3018


Product Standard/Spec. AS/NZS 4131 – Polyethylene (PE) compounds for pressure pipe and fittings

Confirmation No. StandardsMark Licence PST20138

Issuing certification body SAI Global

First date of certification 18 December 2008

Current date of certification 2 August 2016

Expiry date of certification 17 December 2017


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APPENDIX B - WSA PRODUCT SPECIFICATION


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APPENDIX C - SUPPLIER CONTACTS

Iplex Pipelines (Australia) Pty Limited

Corporate Office Level 4, 68 Waterloo Road Macquarie Park NSW 2113 Locked Bag 3501 North Ryde BC NSW 1670 Toowoomba Manufacturing & Distribution Lot 1 Witmack Rd Toowoomba QLD 4350 Thurgoona Manufacturing & Distribution 31 Terry Court, Thurgoona NSW 2640 P.O. Box 5037 Murray Regional Post Office

For all sales and product enquiries call the Iplex Customer Service Centre on: Phone:

Plumbing, Irrigation and Hardware: 13 18 40 Civil: 13 10 86 Electrical: 1800 251 374

Fax:13 18 60

Civil, Mining and Telecommunications sales enquiries: QLD/NT: [email protected] NQ: [email protected] NSW: [email protected] VIC/TAS: [email protected] SA: [email protected] WA: [email protected] Technical Services: [email protected]









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APPENDIX D – IPLEX MILLENNIUM® PIPE


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Melbourne Office

Level 8, 401 Docklands Drive Docklands VIC 3008

Phone: (03) 8605 7666 Fax: (03) 8605 7612 Sydney Office

Level 11, 39 Martin Place Sydney NSW 2000

GPO Box 915 Sydney NSW 2001

Phone: (02) 9221 5966 Fax: (02 9221 5977

www.wsaa.asn.au

http://www.wsaa.asn.au/

Documents

Iplex Pipelines (Australia) Pty Ltd · Millennium PE pipe_Peer Review final.docx Peer Reviewers ... e.g. PE 80 and PE 100, were introduced with greater resistance to both stress cracking