PLUMBING WORKS
A. INTERNAL WORKS - Water Lines
1. Internal pipe work in Toilets and Kitchen to be concealed and carried out as per working drawings.
2. As per the heights mentioned in plumbing drawings, mark the line on walls by chalk in proper alignment and plumb
3. Start chasing of line using a chasing machine or chisel and hammer. The chasing should be done keeping the following points in mind.
Depth - Should not be more than pipe size
Width - Sufficient to accommodate the pipe line
Alignment - Straightness should be considered
Height - For all fittings height as given in Drawing
5. Check Class / Specifications of Materials.
High Pressure threaded Blue UPVC Pipes of Schedule 80 to be used for cold water pipes made of ASTM IS-1785 and threaded as per IS 1239 (Part I)
Class 1 Copper pipes as per BS 2871 Part 1 and fittings as BS 864 Part II should be used for Hot Water.
G.I Fittings should be used for cold water – pipe work as per IS 1239 (Part II)
6. Prepare pipe-skeleton and check all joints for proper tightness. Only approved make pipes, pipe fittings and accessories including jointing materials should be used
7. Groove chasing should not exceed 30 mm after rough plaster for cold water supply line and cold feed line and 50 mm for hot water supply lines.
8. While threading UPVC pipe at site, ensure square cut of pipe ends, chamfer the ends with a file, insert proper size wooden plug in the pipe end and then carryout threading. The sharp edges of gripping vice and other handling tools should be muffed with a suitable packing to prevent damage of pipe surface.
9. The joints should be made with hand tightening of the fitting over pipe and covered with proper layer of Teflon tape. To make the joint permanent, one to two turns over the hand tightened joint is sufficient. Avoid over tightening as this may damage both the pipe and fittings.
10. Special care should be taken while connecting UPVC pipe with G.I Fittings. High quality shellac should be used for jointing.
11. Water tightness of line to be checked using pressure testing equipment. All other openings should be plugged except end portions to which pressure gauge machine is connected.
12. The pressure reading should be above 7 kg/cm2 (80 PSI); and there should not be even a single drop of water coming out of the joints during testing. The duration of the test is 24 hours.
13. Apply bitumen paint over the G.I pipe work.
14. All the bore pieces projecting out should be minimum 200 mm from plastered surface.
15. Cover the skeleton including fittings with good quality Hessian cloth and tie it properly for cold water pipe work.
16. Fix the skeleton in wall using 40 mm plumbing nails at a distance of 230 mm on alternate side.
17. Do the pressure testing once more after fixing in position and ensure no leakage.
18. Keep a gap of 10 mm between all pipes and fittings to accommodate thermal expansion and contraction of pipes for longer life of the system.
19. Horizontal lines within bathrooms should be cement encased and tested before compacting of sunken floor to avoid any accidental damages.
20. Curing should be done over the plaster for at least 7 days.
Installation Guide For Copper Pipes (Hot Water Lines)
1. Make sure that you have the correct size fittings and tube.
2. Prepare the end of the tube by cutting to the correct length with a tube cutter or fine bladed hacksaw. The ends of the tube must be cut square to the axis and be especially careful not to damage the ends of the tube. After cutting the tube, you will notice some rough edges around the outside and inside of the tube. This is called burr and should be removed with a file or sharp blade.
3. Clean the outside surface of the tube that will eventually go into the socket of the fitting, along with the inside surface of the fitting.
4. Apply water soluble flux to the tube and fitting by smearing a thin film of FLOWFLEX Flux around the outer ends of the tube that have been cleaned and to the inside of the cleaned socket of the fitting. This is best done with a small brush to avoid applying too much and to prevent contact with the skin.
5. Insert the tube into the fitting and push home until the stop is reached and wipe off any excess flux with a clean cloth.
For Integral Solder Ring Fittings (Inbuilt):
6. Apply heat to the assemble joints to be made using a conventional blow Lamp torch or similar appliance that emits flame that is clean, blue and soot-free. Once a complete ring of solder has appeared around the mouth of the fitting, turn off the heat. The complete silver coloured ring of solder is proof of a sound joint.
For End feed Fittings:
7. Apply the flame to the fitting to heat tube and solder cup of fitting until solder melts when placed at the joint of tube and fitting. Allow the joint to cool without disturbance.
8. Remove the flame and feed solder into the joint at one or two points until a ring of solder appears at the end of the fitting. The correct amount of solder is approximately equal to 1 ½ the diameter of the fitting ¾” long solder for 15mm fitting etc.
9. Wipe off any excess flux and residues, with wiping cloth after the joints cooled
B. INTERNAL WORKS - UPVC TRAPS
INSTALLATION:
1. Determine correct location of ‘P’/ ’Q’/ ‘S’ Traps and set it on a firm base located relative to the floor finish by pouring concrete on a slab.
2. Bedding can be carried out by pouring concrete around ‘P’/ ’Q’/ ‘S’ Trap; ensuring that outlet of Trap is left clear on concrete.
3. Apply rubber lubricant on W.C. connector ring as well as on outer side of WC pan
4. The outlet can be inserted in the socket end of pipe / fittings (as the case may be) and joint can be solvent cemented to make a leak proof joint.
JOINTING INSTRUCTIONS
1. Make sure the spigot end and inside of the socket is clean and the sealing ring is placed evenly in the socket.
2. When cutting pipes, make sure they are cut square. Chamfer the end cut to an angle of 15 0 with a medium file. Cutting of pipes should be straight, as diagonal cutting leads to leakages
3. A correct depth of entry of the spigot into the socket is required to allow thermal movement. To achieve this, push spigot fully into the socket (remove sealing ring at this time) and make a mark on the spigot. Withdraw the spigot by 10 mm & mark the spigot with the bold line. This bold mark indicates the correct depth of entry to allow the necessary expansion gap.
4. Smear rubber lubricant evenly on the chamfered spigot and the sealing ring. Then insert the spigot into socket with light twisting motion. Pull out the pipe to allow 10 mm expansion gap.
5. Maximum Support Distance In Meter:
Size in mm
|
40 |
50 |
75 |
110 |
160 |
|
Horizontal |
0.4 |
0.5 |
0.75 |
1.1 |
1.6 |
|
Vertical |
1.2 |
1.5 |
2.00 |
2.00 |
2.00 |
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