Page 1 of 20Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev.: 1.0 RDSO SPECIFICATION OF PERMANENTLY LUBRICATED HDPE DUCT SPECIFICATION NO. RDSO/SPN/TC/45/2006 Revision 1.0 Number of Pages : 20 TELECOM DIRECTORATE RESEARCH DESIGNS & STANDARDS ORGANISATION LUCKNOW-226011 Page 2 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev.: 1.0 DOCUMENT DATA SHEET Specification RDSO/SPN/TC/65/2006 Title of Document RDSO Specification of Permanently Lubricated HDPE Duct Author Revision 1.0 Shri Anil Kumar Mishra Director/ Telecom-II/ RDSO Approved by Shri M. Alam Executive Director/ Telecom/ RDSO Abstract This document specifies technical specification of Permanently Lubricated HDPE Duct. : 1.Page 3 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev.0 DOCUMENT CONTROL SHEET NAME ORGANIZATION RDSO FUNCTION Member LEVEL Prepare Director/ Telecom-II Executive Director/ Telecom RDSO Approve REVISIONS: Version Chapter/ Annexure All Pages Revision Effective Month/Year 2002 2006 RDSO/SPN/TC/45/2002 RDSO/SPN/TC/45/2006 FIRST ISSUE Revision 1.0 . In the absence of IRS specification. the specification is given an IRS number and issued as Indian Railway Standard Specification. STT/G/MSG/89 dated 27/03/2002. RDSO/ SPN specification is issued as draft specification for discussion.Page 4 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. 2000/ Tele/ TC/ 3/ Vol. . SUMMARY This document covers the requirement of permanently lubricated high density polythene duct (PLB-HDPE Duct) for use as underground cable conduits for armoured optical fibre cable.0 I. This specification is circulated to customers/ Railways and field inspection units for comments. SOURCE Draft specification RDSO/ SPN/ 35-2002 has been prepared by RDSO. After approval from Railway Board. procurement may be made as per RDSO/ SPN specification. III. RDSO/ SPN along with comments received from various quarters is discussed in Telecom Standards Committee Meeting (TCSC). Recommendation made by TCSC is put up to Railway Board for approval.: 1. Lucknow as per Railway Board letter no. II. FOREWORD Research Designs and Standards Organisation (RDSO) is an attached office of Ministry of Railways. engaged in design and standardization of equipment for use on Indian Railways. II dated 21/02/2002 (excluding pin point requirement) and minutes of 3 rd MSG meeting No. A Annexure . 1.0 4.0 6.0 7. No.0 9.F Annexure .J Annexure .0 11.G Annexure .0 Item Scope Reference Abbreviations General Requirement Technical Requirement PLB HDPE-DUCT Accessories Packing Requirement Type tests Acceptance tests Inspection Warranty Rejection Ordering Information Annexure .B Annexure .0 13.0 5.0 2.I Annexure .C Annexure .H Annexure .Page 5 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev.D Annexure .0 12.E Annexure .0 10.0 8.K Page No.: 1. 6 6 6 6 8 10 11 11 12 12 13 13 13 15 15 15 15 15 16 17 17 17 18 19 .0 TABLE OF CONTENTS Sr.0 3. American Society for Testing & Materials. 2.: 1. PLB ---.Indian Standard. 7328.Permanently Lubricated UV ---.0 SCOPE : This document covers the requirement of Permanently Lubricated High Density Polyethylene (PLB-HDPE duct) duct for use as underground cable conduits for armoured optical fibre cable. . MFR ---.0 1.Page 6 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev.Ultra Violet. low friction boundary layer between the inner surface of the duct and armoured optical fibre cable.0 GENERAL REQUIREMENTS: The PLB-HDPE duct shall consist of two concentric layers. D-1603.0 ABBREVIATIONS • • • • • • • • • ASTM ---.Cubic Centimeter. The lubricant shall be of a solid layer of uniform thickness so formulated to provide a permanent.Melt flow Rate. MFI ---. 121505.Specification Provisional Number.0 REFERENCES In preparing this standard assistance has been taken from the following : (i) DOT Specification No. G/CDS – 08/ 01 DEC. 4. It is suitable for cable installation by blowing technique or by direct underground burial. IS 4984. 4. 12235(Part-9) (iii) ASTM . 99 (ii) IS specification No. 638.Melt Flow Index. SPN ---. usage and through out the life of duct. The HDPE outer layer shall be co extruded with an inner layer of solid permanent lubricant to reduce the internal co-efficient of friction (ICF).1 Outer Layer: The base HDPE resin used for the outer layer of the permanent lubricated HDPE Duct shall confirm to IS 7328 or to its equivalent. IS ---. D – 1238. D – 2240.D – 1693. 3. 4. CC ---. D – 3895.High Density Polyethylene.2 Inner Layer: The inner layer of solid permanent lubricant shall be continuous all through and shall not come out during storage. 9938. HDPE ---. 4. 4.3.3 Requirements of Raw Materials used for the Duct: 4. In the finished permanent lubricated HDPE duct.3 Single pass rework material of the same composition produced from the manufacturer’s own production shall be used and it shall not exceed 10% in any case.3. 4. 4.6 The raw material used in the manufacture of the duct shall be such that the service life of the duct and all its accessories can be expected to be more than 50 years including the life of permanent lubricant. 4.3. However temporary increase in temperature +700C should not result in any detoriation.3.0 The inner lubrication material shall be of friction reducing polymeric material.3.5 Suitable UV stabilisers shall be used for manufacture of the duct to protect against UV degradation.1%. 4.Page 7 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. The lubricant material shall have no toxic or dermatic hazards for safe handling.1 The anti-oxidants used shall be physiologically harmless. .3.) (b) (-)200C to (+)650C.: 1. which shall be integral with HDPE layer. the co-extruded inner layer of solid permanent lubricant shall be integral part with HDPE and shall be white in colour and clearly visible in cross-section of duct. when stored in open for a minimum period of 8 months. 4.2 None of the additives shall be used separately or together in quantities as to impair long term physical and chemical properties of the duct.4 The raw material used for extrusion shall be dried to bring the moisture content to less than 0.4 Service Condition: The lubricated HDPE Duct shall be able to withstand the following environmental conditions: (a) Ambient temperature : over which Specifications are guaranteed Storage temperature 00C to +550 C (50% RH Max. 4 mm 1000 + 100 meter Should be min. A.20 mm Annexure – A Out side diameter Standard length Lubricated layer thickness Ovality test Weight per coil CHEMICAL TESTS 40. 5. flaking. free of blisters. 2. 6. • Date of manufacture • Sequential length marking at every meter DIMENSION AND WEIGHT Wall thickness 3. RDSO/SPN/45/2006 • I. Identification marking Permanently marked with indelible ink • Specification No.0 TECHNICAL REQUIREMENT: Parameter APPEARANCE Visual appearance Specified Limit Test Method S. Smooth inside & out side surface. C.: 1. 4.No. The colour of the inner layer shall be white. cable duct • Laser symbol • Manufacturer’s name • Name of the duct with size • Serial number of the duct. hole. 10% of wall thickness Difference of maximum & minimum diameter should be less than 1.Page 8 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. uniform in thickness. scratches & roughness. Colour The colour of the duct shall be IS : 9938 orange/green and uniform throughout. 1. 3.50 mm + 0. shrink. Lubricated layer Must have inner lubricant layer clearly visible & white in colour . 2. 1. 3.3 mm 385 gm/ meter +/.5 gm Annexure – A -Annexure – A IS 4984 -- .R.0 5.0 mm + 0. B. 4. 4.E Annexure . 5. 3. 1. 11.940 to 0. E. 2.2 to 1.0 1. 12. 9. 2.D after recovery less than 2% No crack or split IS 12235 (Part -9) < 0. 10.958 g/cc at 270C Min. Air Tightness Test of End Plug shall be tested with a .: 1. 6. 2.H Annexure .Page 9 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. 13.F Annexure .06 Mandrel should easily pass between one end to other No snaking or waving having zero coil set At 800 C minimum holding time 165 hrs Induced stress 3. ASTM D 1238 ASTM D 1603 ASTM D 1693 Annexure – B ASTM D 3895 Annexure – C ASTM D 2240 ASTM D 1505 ASTM 638 ASTM 638 Environmental Stress No cracking cracking resistance ESCR Oxidation Induction 30 minutes (minimum) test UV stabliser content Shall not be less than 0.2% max. 8. 4. 3.05% PHYSICAL TESTS Hardness Density Tensile strength at speed of testing 100 + 10 mm/ minute Elongation at Break Heat Reversion Crush Resistance test Impact strength Coefficient of friction Mandrel Test Coil test Hydraulic characteristics Optical Fibre Cable blowing test Termite test 60 Shore D (min) 0. 600% < 3% IS 4984 Deflection not greater than 10% and Annexure . D.5 Mpa No visible damage No termite effect Annexure . Melt flow index Ash content 0.G IS 4984 Annexure . 1. 7. Pull Strength of The pull strength of the coupler Annexure – K coupler shall not be less than 408 Kg. 20 N/mm2 Min.I Annexure – J TESTS ON PLB HDPE DUCT ACCESSORIES Coupler Leakage The coupler jointing shall meet the Test air pressure test of 15 Kg/ cm2 for a -minimum period of 2 hours. 5 Kg load 0. 5.1 gm/10 min at 1900C. 3. 6. procedure and method for installation and type/grade of the material used for the accessories.3 Cable Sealing Plug: This is used to seal the ends of the ducts perfectly. 6. etc. pressure of 1 bar for 30 minutes.: 1. The required quantities of accessories are to be mentioned by the Purchasing Authority in the purchase order.2 End Plug: This is for sealing the ends of the empty ducts. moisture. The rubber component shall be of nitrile rubber for increased life.1. insects/rodents etc. easy to install and shall provide air tight and water tight leak proof joint between the two ducts. It shall withstand the air pressure test of 15 Kg/cm 2 for a minimum period of 2 hours without any leakage. which enables them to be installed on ducts without pre-dismantling.1. insects/rodents etc into the duct.0 End Plug 4. The manufacturers shall provide complete design details. The rubber component shall be of nitrile rubber for increased life. It is used for jointing two ducts. 6. prior to installation of the OF cable and shall be fitted immediately after laying of the duct.1. This is required at all places where cable has come out of the duct either for jointing or entry into the building as required. (Suitable length shall be taken) Note : All above mentioned tests shall be conducted on finished product.1.1 PLB HDPE DUCT ACCESSORIES: The following accessories are required for jointing the ducts and shall be supplied along with the ducts.Page 10 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. to prevent the entry of dirt. The sealing plug shall be capable of accommodating armoured optical fibre cable as per IRS:TC 552006 taking into account the variation in diameter due to tolerance limits. 6.4 End Cap: . to prevent the entry of any dirt. water.0 6. after the cable is installed in the duct. The design of this shall be simple.1 Plastic Coupler: The coupler shall be of Push-fit type having Push Lock mechanism. 6. (Suitable length shall be taken) Air Tightness Test of Cable Sealing Plug shall be tested Cable Sealing Plug with a pressure of 1 bar for 30 minutes. water. moisture. All the tests as mentioned in clause 5 of this specification excepting cable blow test and termite test shall be carried out on both the coils.2 C-Spanner: This is required to tighten Plastic Coupler properly so as to ensure air/ water tightness as specified above. the air tight sealed duct shall be transported in a vehicle exclusively used for it and no other consignments shall be loaded with it in the same vehicle.0 (D13)] shall be carried out on one coil each.3 8. shall be fitted into both ends of duct coil after manufacturing the duct. Both the coils shall be unrolled and rolled for visual appearance and standard length test.3 8.2 The following additional tools are required for jointing of the ducts and installation of optical fibre cable.Page 11 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev.1 Duct Cutter: This is required to cut the duct ends squarely without any burr or notch.0 8. This shall avoid entry of dust.1 PACKING REQUIREMENT The stores shall be supplied in coils of suitable size for delivery such that minimum inner bending diameter of the coiled duct shall be 20 times the outer Diameter of the duct.2 8.4 8.0 7.2.5 8. Test results shall be taken on standard formats circulated by RDSO. 7. The duct should be sealed with tight end caps of minimum 10 bar pressure. 30 days Termite Test shall be carried out at IICT. Hyderabad as per Annexure – J.6 . 6. 7. TYPE TESTS: Two coils of standard length shall be manufactured for type tests.2.0 (D12)] and Termite test [Clause 5. mud and rain water into the duct during the transit and storage. 6. If transportation is by road.1 8.: 1.2 7. Tests shall be carried out on samples taken both from top end & bottom end.0 This cap is made of hard rubber. Cable blow test [Clause 5. 6. 4 9.: 1.2.4)] 7.Page 12 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev.6 10.0 [D (1.0 and 13.0 (A) 5.9. Sampling Plan: Clause 5.4.7. Standard length shall be verified by unrolling and rolling the coil.10.0 D shall be carried out on samples taken from both top and bottom ends of the coil.5 9.0 [C (1.2 Dimensions as per clause 5.0 B shall be checked at both top & bottom ends. Coils for testing purposes shall be randomly selected as per the sampling plan.3 .3.0[E (1. The purchaser or his nominee shall have free access to the works of the manufacturer and to be present at all reasonable times and shall be given 10. INSPECTION: All the gauges/ test & measuring instruments shall be under calibration control at the time of inspection and proof to this office shall be produced.4)] 5.1 9.0 (B) 5.6.0 10.5. Inspection and testing shall be carried out by the inspecting authority nominated by the purchaser to ensure that all the requirements of this specification are complied with for the acceptance of the materials offered by the supplier for inspection.3 9.3.2. Lucknow shall be used.1 10.11)] 5.0 9.0 C & 5.0 Percentage of lot to be inspected 100% 10% 2 samples per lot 2 samples per lot 2 samples per lot 10% 9.3.2 ACCEPTANCE TESTS: Lot size for acceptance test shall be restricted to 100 coils of standard length per lot. Standard format for acceptance test as circulated by RDSO. Chemical and physical tests as per clause 5.8.2.0 9. 4 The manufacturer shall supply the duct samples and samples of the raw materials free of charge as required by the inspecting authority and shall at his own cost prepare and furnish the necessary test pieces and appliances for such testing as may be carried out at his own premises in accordance with this specification. each of end plug. WARRANTY: The manufacturer shall warrant the material covered by this specification to be free from defects in design. 13. Two nos. cable sealing plug and end cap shall be supplied along with each coil.0 13.0 13. Purchaser may specify additional requirement. However purchaser may specify his own dimensions/ lengths/ packing requirements etc. Failing the existence of facilities at his own premises for the prescribed tests. its proper functioning or reliability. negligence or accident. workshop or test house. In such cases necessary tolerance shall also be specified by the purchaser.0 facilities by the manufacturer to inspect the manufacturing of the duct at any stage of manufacture. He shall have the right to reject whole or part of any work or material that does not conform to the terms of this specification or any other specification or requirement applicable and may order the same to be removed/replaced or altered at the expense of the manufacturer. or which has been subjected to misuse. in manufacturer’s judgment.Page 13 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. fail to pass the tests or comply with the requirement of the specification. 12.: 1. This warranty shall not apply to any apparatus which shall have been repaired or altered in any way by any one other than the manufacturer thereof so as to affect. the whole consignment shall be rejected subject to the discretion of the purchaser or his nominee. 11.0 REJECTION: In case the duct tested and inspected in accordance with this specification.1 ORDERING INFORMATION: Normally the duct will be supplied as per the standard dimensions and length as mentioned in this document. material and workmanship under ordinary use and service. the manufacturer shall bear the cost of carrying out the tests in an approved laboratory.2 . 10. All reasonable/complete facilities considered necessary by the inspecting authorities for the inspection of the cables shall be supplied by the manufacturer free of cost. his obligation under this warranty being limited to replace free of cost those parts which shall be found defective within one year after delivery to the purchaser. 0 13.: 1.Page 14 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. of plastic couplers (No. .4. Purchaser may specify additional requirement. of couplers to make a continuous length of the lot + 10% extra) shall be supplied along with each lot. 13.3 Adequate no. Purchasers may specify additional requirement.1 One set of Duct cutter and C spanner shall be supplied along with each lot. 01 mm. circular test fixture of diameter 750 mm (capable of having secured to it).0 Annexure – A (Dimension of the Duct) The wall thickness and the out side diameter shall be measured with the help of a Vernier Caliper with a least count of . NMR spectra and UV spectra. Pune – 411008. Annexure – E (Internal coefficient of friction Test) Scope : This procedure details the method employed to determine internal friction properties of the duct.Page 15 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. The test shall be carried out at: National Chemical Laboratory. Apparatus : Extensometer machine.: 1. For acceptance testing the duration of the test shall be 96 hours. 25 Kg weight. Homi Bhabha Road. Annexure – C (UV Stabliser Content Test) Identification of UV additive shall be done by FTIR spectra. The deflection with load on and after recovery period shall not exceed 10% and 2% respectively.05%. . The lubricant layer thickness shall be measured with the help of a traveling microscope with a least count of . For type approval testing the duration of the test shall be 1000 hours. Dr. Annexure – B ( Environmental Stress Cracking Resistance Test) ESCR test shall be carried out as per ASTM D 1693.01 mm. optical fibre cable and pulley wheel. Annexure – D (Crush Resistance Test) Sample of duct of 150 mm + 2 mm in length shall be subjected to a dead load of not less than 50 Kg for one minute and shall be allowed to recover for 5 minutes. UV stabiliser content of finished duct shall not be less than 0. when the duct is bent to a radius of 5 meters. The other end of the optical fibre cable shall be attached via a pulley. The extensometer shall be operated. freely throughout the length. (d). A suitable length of armoured optical fibre cable as per IRS : TC 552006 shall be inserted into the sample.0 Method : (a). Extensometer conditions Load : Kg or Newtons Speed : 500 mm/minute Mode : Tension The coefficient of friction shall be calculated by the following equation : Internal coefficient of friction (ICF) = loge ( T1 / T2 )/ Q Where T1 = pulling force. with one end extending vertically 200 mm towards the floor. The extensometer and the test fixture shall be aligned and secured from the movement. . in lifting the 25 Kg weight to a minimum travel of 150 mm shall be noted. Annexure – F (Mandrel Test) A 150 mm long mandrel of diameter. 450 deg = 7.85398 Radians) (b). (f). T2 = 25 Kg Q = Angle of subtending arc between T1 & T2 in radians (i.: 1. A suitable length of the duct. pre-conditioned at 23 + 20C for 2 hours shall be secured to the text fixture such that the sample completes a 4500 deg wrap. 3 mm less than the internal diameter of the duct shall be passed through a 5 meter length of the duct.e. (g). and the maximum load applied. The 25 Kg tail weight shall be attached to the optical fibre cable extending from the 200 mm vertical extension of the sample such that there is a minimum free travel of 150 mm for the weight. to the extensometer such that the planes of travel are in no direction diagonal and there shall be slack remaining in the optical fibre cable. (e).Page 16 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. (c). For this purpose. a sample length of 10 times the outside diameter of the duct shall be taken.) (Min.Page 17 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. Annexure – H (Hydraulic Characteristics) The duct shall be tested for internal pressure creep rupture test as per IS – 4984. At the end of the test.8 Annexure – I (Optical Fibre Cable Blowing Test) For this test an Armoured Optical Fibre Cable as per IRS : TC 55-2006 shall be installed by blowing of the cable in a length of 1 Km of the duct. It shall be inspected for any visual damage. each time in not more than 30 minutes.: 1. except 5 meters from each end. There shall be no visible damage to OFC. The 1 Km section shall include two couplings at suitable locations as shown in the figure. The test showing failure within a distance equivalent to the length of end cap from the end shall be disregarded and the test repeated. It shall be possible to blow in the Optical fibre Cable through the 1 Km duct. the sample shall not show signs of localized swelling or leakage and shall not burst during the test duration. Thus the duct shall lay straight into the trench without recoiling. . The test temperatures and the duration of the test shall be as follows: Test Type Test Acceptance Test Test Temp. it shall be straight without any bends or kinks and without deformation. The OFC shall then be blown out. when a minimum length of 50 meters duct taken from the coil and laid on the ground.0 Annexure – G (Coil Set) The PLB HDPE duct shall unroll off the drums without snaking or waving having zero coil set. 0 C 80 80 Test Duration (Hrs.5 3. For this purpose. The OFC shall then be blown in again. holding time) 165 48 Induced stress (Mpa) 3. The test will be conducted on two samples out of the five submitted for Type Approval. The duct shall be laid with bends in the horizontal and vertical planes and a rise in the middle as detailed in the figure –1. Test duct will be cut into suitable lengths and their edges will be smoothened with the help of sand paper. The percent weight loss in each sample will be calculated and compared with control samples. scraping. Based on the results the appropriate rating will be allotted to the sample as follows : Rating Chart : Degree of damage OK Nest Building Surface nibbling Slight attack Attack Destroyed Characteristics of damage Undamaged Formation of nest building on the surface of the test samples. After removal of affixed mud and debris. restricted regions Surface deeply pitted. The test samples will be removed carefully after 30 days from the respective places and observed the formation of nest building on the surface of the test samples. One set of test pieces consisting five replicates will be buried at a depth of 1½ feet in the termite mounds (field conditions) and another set will be placed in termites inhabiting soil (laboratory conditions) for a period of 30 days to study two sets of test pieces will be placed in identical conditions with out any termites and termed as controls. .Page 18 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev. Hyderabad as per their standard operating protocol (DOP-TOX-E1. The initial weight of each labeled sample will be recoded by an analytical balance. without caps) will be recorded. ISO 9002. samples will be evaluated visually under magnification for any feeding marks like nibbling. The final weight of each labeled sample (after exposure. pitting and perforation on the surface. IICT). shallowly pitted over extensive areas Sample perforated Rating -0‘ NB’ ‘SN’ ‘SA’ ‘A’ ‘D’ A rating of – 0 – shall indicate that the sample has successfully passed the termite resistance test.0 Annexure – J ( Termite ResistanceTest) Termite Resistance Test shall be carried out at IICT. and appropriate suitable caps will be fixed on both ends before commencement of the experiment.: 1. Surface roughened by the termites but not pitted Surface with shallow pits and only in a few. The free ends of the 2 ducts are fitted to the two suitable grips of a tensile testing machine.Page 19 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev.5 mm/ min.: 1.5 + 0. each 30 cms. under test.0 Annexure – K (Pull strength of coupler) 2 Duct samples. . The joint is then pulled apart with the help of the tensile testing machine at a speed 12. are jointed with the help of the Coupler. Maximum force required to separate the joint is then measured and noted. long. Page 20 of 20 Effective from: 28/12/2006 RDSO/ SPN/ 45/2006 Rev.0 .: 1.