Injection Moulded/Machined High-Density Polyethylene (HDPE) Fittings for Potable Water Supplies, Part 6: Specific Requirements for Pipe Ends
2003 Edition

Overview of Scope for HDPE Pipe Ends

• Manufacturing Methods by Size:

  • For diameters between 20 mm and 315 mm: Injection moulded and optionally machined.
  • For diameters 355 mm and above: Machined from thick-walled extruded pipes or compression moulded slabs.

• Referenced Standards:

  • IS 8008 Part 1: General requirements for injection moulded/machined HDPE fittings.
  • IS 4984: Specification for HDPE pipes used in water supply.

• Rounding Off Rules:

  • Numerical results are rounded following IS 2:1960.
  • Significant figures retained as specified in the standard.

• Related Parts in IS 8008 Series:

  Part	Description
  1	General requirements for fittings
  2	Specifications for 90° bends
  3	Specifications for 90° tees
  4	Specifications for reducers
  5	Specifications for ferrule reducers
  7	Specifications for sandwich flanges
  8	Specifications for reducing tees
  9	Specifications for end caps

The scope defines the manufacturing routes and references applicable fitting standards to ensure potable water system compliance.

flowchart LR
    A[Pipe Ends 20-315 mm] -->|Injection Moulding + Machining (if needed)| B[Finished Pipe Ends]
    C[Pipe Ends ≥355 mm] -->|Machining from Extruded Pipes or Slabs| B
    B --> D[Application in Potable Water Systems]
    D --> E[Compliance with IS 8008 and IS 4984]

Key References and Dimension Tables for IS 8008 Part 6

1. Standards Overview (Foreword Table)

2. Dimensional Data for Injection Moulded and Machined Pipe Ends (Clause 3.2.2)

Tolerances:

• D, D4, Z: ±2 mm
• H, L: ±1 mm

3. Rounding Protocol (IS 2:1960)

• Test and calculated values must be rounded maintaining the same significant figures as specified.

4. Certification and Marking (Clause 4)

Manufacturing Guidelines per IS 8008 Part 6

• General Requirements: Manufacturing shall adhere to IS 8008 Part 1:2003, covering material specifications, grading, sizing, performance requirements, testing, sampling, and inspection.

• Production Methods (Clause 1.2):

  • Diameters from 20 mm to 315 mm: Produced using injection moulding with machining applied as necessary.
  • Diameters 355 mm and above: Created by machining thick-walled extruded pipes or compression moulded slabs.

• Applicable Standards:

  IS Number	Title
  IS 8008 Part 1:2003	General prerequisites for injection moulded/machined HDPE fittings
  IS 4984:1995	HDPE pipes for potable water

Manufacturing Methods Summary by Pipe End Size

This approach guarantees dimensional precision, material quality, and compliance with potable water supply norms.

flowchart LR
    A[Pipe Ends 20-315 mm] --> B[Injection Moulding]
    B --> C[Machining (as needed)]
    D[Pipe Ends ≥355 mm] --> E[Machining from extruded pipes or compression moulded slabs]

Marking Specifications for HDPE Pipe-End Fittings (IS 8008 Part 6)

Marking Essentials (Clauses 4.1 & 4.2)

• Each pipe-end fitting must be marked with:

  • Manufacturer’s identification
  • Fitting size
  • Material grade
  • Pressure class (working pressure rating)

• BIS Certification Mark:

  • Optional use of the BIS Standard Mark as per the BIS Act, 1986.
  • Usage subject to BIS licensing.

Key Dimensions for Pipe Ends (Table 1, Clause 3.2.2)

Tolerances for Dimensions:

Marking Overview Diagram

flowchart TD
    A[Pipe-End Fitting] --> B[Marking Details]
    B --> C[Manufacturer ID]
    B --> D[Fitting Size]
    B --> E[Material Grade]
    B --> F[Pressure Class]
    B --> G[BIS Standard Mark (Optional)]

Dimension and Tolerance Criteria for HDPE Pipe Ends (IS 8008 Part 6)

Core Dimensions (Clause 3.2.2 & Table 1)

See full Table 1 in the standard for all sizes.

Permissible Tolerances

Notes:

• Laying length Z represents the overall fitting length for installation.
• Collar height H and weld length L vary with pressure class (PN 6 or PN 10).
• Accurate dimensions ensure proper jointing and welding quality.
• Refer to illustrative Fig 1 in the standard for visual dimension reference.

flowchart LR
    A[Nominal Diameter] --> B[Manufacturing Reference Diameter D3]
    B --> C[Collar Diameter D4]
    C --> D[Laying Length Z]
    D --> E[Collar Height H]
    E --> F[Welding Length L]

Material Requirements Overview (IS 8008 Part 6)

• General Material Criteria: Detailed specifications are provided in IS 8008 Part 1 (2003), covering:

  • Material grades and types suitable for potable water service.
  • Manufacturing processes relevant to HDPE fittings.
  • Performance and durability requirements.
  • Mechanical and chemical testing methods.
  • Sampling and inspection protocols to assure quality.

• Component-Specific Standards: The IS 8008 series includes parts dedicated to various fitting types:

  Part	Component	Focus Area
  2	90° Bends	Material and dimensional requirements
  3	90° Tees	Material and dimensional requirements
  4	Reducers	Material and dimensional requirements
  5	Ferrule Reducers	Material and dimensional requirements
  7	Sandwich Flanges	Material and dimensional requirements
  8	Reducing Tees	Material and dimensional requirements
  9	End Caps	Material and dimensional requirements

• Key Material Properties to Verify:

  • Yield strength
  • Tensile strength
  • Impact resistance
  • Resistance to corrosion

Illustrative Material Specification Table

Notes:

• Reference the relevant IS 8008 part for detailed material criteria per component.
• Testing methods follow IS 8008 Part 1 protocols.
• Rigorous sampling and inspection ensure manufacturing conformity.

flowchart LR
    A[Material Requirements] --> B[General Criteria - IS 8008 Part 1]
    A --> C[Specific Fittings & Components]
    C --> D[90° Bends - Part 2]
    C --> E[90° Tees - Part 3]
    C --> F[Reducers - Part 4]
    C --> G[Ferrule Reducers - Part 5]

Welding and Jointing Specifications (IS 8008 Part 6)

• Consistent Weld Length: Welding length is maintained uniformly with set tolerances to assure joint strength.
• Rewelding Permission: In cases where welds fail inspection, rewelding is permitted following defined procedures.
• Pipe End Dimensions for Welding:
  • Outer diameter and wall thickness must conform to Clause 8 of IS 8008 Part 1.
  • Ensures proper alignment and fit-up of welded joints.

Relevant Related Parts:

Typical Welding Parameters:

Process Flow Diagram

flowchart TD
    A[Pipe Ends] --> B[Verify OD & Thickness per IS 8008 Part 1]
    B --> C[Prepare Pipe Ends for Welding]
    C --> D[Conduct Welding]
    D --> E{Is Weld Acceptable?}
    E -- Yes --> F[Final Inspection]
    E -- No --> G[Perform Rewelding]
    G --> D

Inspection and Testing Overview for IS 8008 Part 6

1. General Requirements (Clause 3.1): Material properties, manufacturing processes, grading, sizing, performance criteria, testing methods, sampling, and inspection procedures must comply with IS 8008 Part 1.

2. Rounding Off Results: Final measurement and test results should be rounded following IS 2:1960 to maintain the number of significant digits specified.

3. Dimensional Checks (Clause 3.2.2, Table 1): Includes nominal diameter, collar diameter, laying length (Z), collar height (H), and welding length (L) for pressure classes PN 6 and PN 10.

4. Tolerances:

   • Manufacturing diameter (D): ±2 mm
   • Collar diameter (D4): ±2 mm
   • Laying length (Z): ±2 mm
   • Collar height (H): ±1 mm
   • Welding length (L): ±1 mm

(Refer to the complete table for all sizes)

5. Certification Marking (Clause 4.2.1): Use of the BIS Standard Mark follows the Bureau of Indian Standards Act, 1986.

Inspection Workflow Diagram

flowchart TD
    A[Start Inspection] --> B[Material Verification]
    B --> C[Dimensional Measurement]
    C --> D[Testing (Mechanical, Chemical)]
    D --> E[Check Compliance with IS 8008 Part 1]
    E --> F[Approve or Reject]

Bureau of Indian Standards (BIS) Certification Marking (Clause 4.2)

• The use of the BIS Standard Mark on pipe-end fittings is regulated under the BIS Act, 1986.
• Manufacturers must secure a license from BIS to affix the Standard Mark.
• This marking serves as confirmation of conformity with IS standards and quality benchmarks.

Dimension Summary for Injection Moulded and Machined Pipe Ends (Clause 3.2.2)

Refer to Clause 3.2.2 for full details.

Permissible Dimensional Tolerances

Certification Marking Process

flowchart TD
    A[BIS License Granted] --> B[Affix Standard Mark]
    B --> C[Marking on Pipe-End Fittings]
    C --> D[Conformance to IS 8008]
    D --> E[Quality Assurance]

Supporting Tables and Illustrations from IS 8008 Part 6 (2003)

1. Dimensional Data for Injection Moulded and Machined Pipe Ends (Clause 3.2.2)

Complete dimensional table available within the standard document.

2. Dimension Tolerances

3. General Notes

• All measurements are in millimeters.
• Rounding of numerical test results follows IS 2:1960.
• Use of BIS Standard Mark complies with BIS Act, 1986.

Dimensional Relationships Diagram

flowchart LR
    D[Manufacturing Reference Diameter (D)] --> D4[Collar Diameter (D4)]
    D4 --> Z[Laying Length (Z)]
    Z --> H[Collar Height (H)]
    H --> L[Welding Length (L)]