UPVC PIPES AND FITTINGS

SAPPCO DAMMAM FACTORYBranch of Saudi Plastic Products Co. Ltd.C.R. 2050050912

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DAMMAM PORT

AL QAHTANIPIPE COATING

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RIYADH ROAD

SABIC MARKETING

DAMMAM TOWERS

DAMMAM

SAPPCO

SAPPCO after Sales ServiceProvides its customers with advice on any

technical problems they may encounter

For further details and information, contact

SAPPCO DAMMAM FACTORYFACTORY & MAIN OFFICES

FIRST DAMMAM INDUSTRIAL ESTATE - 8TH STREETP.O. Box 4916, Dammam 31412, Saudi Arabia

Telephone : (03) 847-1703 / 847-3323Telefax : (03) 847-1969

Key facts you should know about SAPPCO UPVC pipe

It’s costing less. While the cost of almost everything else has been going up, the cost ofUPVC pipe has been decreasing.

It’s easy to handle Because of it’s light weight and lack of fragility. It needs fewer men to handle it quicker.

It has a smooth boreWhich means betterflow characteristicsand no buildupof corrosionproducts.

It’s simple to joiningWith its integral push-fitself sealing action.Long runsof UPVC pressure pipe can be installed in record time.

It’s corrosion free.UPVC pipe just does not

corrode; it’s impervious toattack from aggressive soils,

water and most commonacids and alkalis.

Publication P.3, Issue 5March - 2009

SAPPCO UPVCpipe is suitable

for workingpressure up to

16 barat 20°C.

SAPPCO THE LEADING MANUFACTURER OF PLASTIC PIPES

SAPPCO THE LEADING NATIONAL FACTORY FOR UPVC PIPES

e-mail: sapdam@sappco.com.sa/info@sappco-dammam.com

RIYADH OFFICE : P.O. Box 2828, Riyadh 11461, Tel.: (01) 4480448 - Fax : (01) 4461392JEDDAH OFFICE : P.O. Box 5448, Jeddah 21422, Tel.: (02) 6749402, 6726318 - Fax : (02) 674 7827

Every care is taken to see that information given in this catalogue is correct and current but it is not intended to form\any part of any contract; and no warranty is intended to be given or implied in respect of the contents hereof.

Web site : http//:www.sappco-dammam.com

LOCATIONMAP

For Water SupplyIrrigation SystemsSoil, Waste DischargeDrainage & SewerageCable Ducts and Conduits

NOTES :

SAPPCO Dammam Factory

SAPPCO UPVC, with Rubber Seal Joint 3

Foreword

SAPPCO DAMMAMFACTORY

There has been a tremendous growth in the industrial, commer cial, and housing sectors and in all types of public amenities in Saudi Arabia. For this growth, pipelines are needed to convey water and sewage, and to protect telecommunication and elec trical cables. To fulfill this need, Saudi Plastic Products Co. Ltd. was formed with the aim of producing, in Saudi Arabia, a full range of unplasticised polyvinyl chloride (UPVC) pipes and fittings to internationally recognised standards and Saudi Arabian Standards.

SAPPCO-DAMMAM also manufacture:

- CPVC pipes for Hot water distribution systems

- Polyethylene (PE100/PE80) pipes for various services

applications

- Polyethylene sub-duct/miniduct for Fibre Optic

Cable/Telecom.

- PVC pipes to American Standards

Our model factory in Dammam Industrial Estate is equipped with the most advanced extrusion systems available today and we are able to supply complete UPVC, CPVC and HDPE pipelines at relatively short notice for either new projects or additions to, or replacement of, existing pipe lines.

We are confident that pipe of our manufacture is especially suited to the needs and environment of Saudi Arabia and the surrounding Countries and are proud that SAPPCO by pro ducing pipes locally is contributing to the industrialisation of Saudi Arabia.

SAPPCO DAMMAM FACTORY was formed with manufacturing ca pacity of 14000 Tons of pipe products.

Our affiliated company APLACO in Riyadh manufactures UPVC and CPVC pipe fittings designed to standards for use with SAPPCO pipes. The Comprehensive range of fittings is available from our factory stores.

4

Introduction This is a technical handbook for the engineers who designs and

installs water and sewage pipelines and it contains the most

up-to-date information now available, based on world wide know how

and technical knowledge.

The period of pioneering the use of UPVC pipes for the distribution of

water and sewerage is past and UPVC is widely established

throughout the world because of it’s many advantages over other

materials.

High quality pipes are manufactured within a EN ISO 9001:2008

certified quality management system.

In addition to the Riyadh Plant SAPPCO have built a model factory in

Dammam and equipped it with the most modern machinery available,

using many automated techniques to produce UPVC pipes to

exacting standards.

The accumulated knowledge of our Technical Advisors is freely

offered to engineers and our Technical Service Department is

available at all times to offer guidance and advice on the use of

SAPPCO UPVC pipes.

Consultants and Engineers are welcome to visit our offices, factory

and laboratory at the Dammam Industrial Estate, Dammam-Alkhobar,

Highway, for full discussions and to assure themselves that our

production and testing facilities are of the highest order.

We also cater for the Telecommunication and Electrical Engineer with

the supply of UPVC conduits and Ducts. For any information please

contact our Technical Sales Engineers.

5

PROPERTIES

MATERIAL : Unplasticised Polyvinyl Chloride (UPVC)

TABLE 1 : All values at 23°C unless otherwise specified

General Properties: Density g / cm3 1.42Water absorption (boilingwater x 24h) mg / cm2 <4Poisson’s Ratio - 0.35 - 0.38Friction Co-efficient, Hazzen William Factor “C” 150 Mechanical Properties:Tensile strength ultimate MPa >52Modulus of Elasticity in tension MPa 3180Compressive strength MPa 65.5Flexural strength MPa 93Izod Impact strength J/m of notch 55-60Hardness (Rockwell) R 119 (Durometer) D >70±3

Thermal Properties:Deflection temperature °C > 78 Vicat softening temperature °C > 80 Co-efficient of linear Th-Expansion mm/m °C 0.08Specific Heat Kcal/kg°C 0.23Thermal conductivity W/m °C/m2 0.15

Flammability Properties:Flammability (resistance) Resistance Self ex tin guishing (UL-94/0.062”) Rating V-O

Electrical Properties:Dielectric Constant 60 cps @ 30°C 4.00Dielectric Strength volts/mil 1100Volume resistivity ohm.cm > 1014

Note : 1.1 : This data is based on information obtained from samples tested or provided by material manufacturer. It should be used as a general rec ommen dation only and not as a guar an tee of per formance or longevity.6

PROPERTY UNIT VALUE

MaterialClassification

ManufacturingStandards

ChemicalResistance

SAPPCO pipe is made from unplasticized Polyvinyl Chloride UPVC Compound fully meeting the requirements of the manufacturing standards. SAPPCO UPVC Compound consist substantially UPVC resin and to which only those additives are added which facilitate the production of sound, durable and high quality pipes fully conforming to the requirements of all relevant manufacturing Standards.

SAPPCO manufacture UPVC pipes to ISO 161-1 Metric Series specifies the nominal outside diameters for conveyance of fluids in pressure and non-pressure applications. It also specifies nominal pressure rating, MRS and overall service (design) Coefficients for thermoplastic pipes for pressure application. Table 3 describe the manufacturing standards.

SAPPCO PVC Pipe satisfy therequirements of DIN 8061 supp. 1and ISO/TR 7473. Our pipe hasex cellent chemical resistance tostrong acids and bases.

TABLE 2 : MATERIAL CLASSIFICATION

TABLE 3 : PIPE MANUFACTURING STANDARDS

ORGANIZATION

STANDARD DESCRIPTION CLASSIFICATION VALUEEN ISO 12162 CLASSIFICATION PVC-U 250

EN ISO 12162 MIN. REQUIRED STRENGTH MRS, 25 MPa

ASTM D 1784 CELL CLASS 12454

ASTM D 1784 DESIGNATION PVC 1120

COUNTRY

SAUDI ARABIA

EUROPIANS

INTERNATIONAL

SSA

DIN

DIN EN

BS EN

ISO

14, 15, 255

8062, 16873, 16875

1329-1, 1401-1

1329-1, 1401-1, 1452 (imperial)

161-1,3633, 4435

CODE STANDARD NUMBER

Strong OxidantsHalogens

Fig 1

Weak AcidsWeak BasesSaltsStrong AcidsStrong BasesAll kind of water

Aromatic SolventsEsters & Ketones

Aliphatic Solvents

Excellent

GoodFairPoor

7

SAPPCO UPVC Pipe Dimensions

TABLE 4 : SAPPCO UPVC Pipe dimensions based on SSA 14, DIN 8062 and ISO 161-1

Nominaloutside

diametermm

NominalWallmm

NominalWallmm

NominalWeightKg/m

NominalWeightKg/m

NominalWallmm

NominalWeightKg/m

NominalWallmm

NominalWeightKg/m

CLASS 2PN 4

CLASS 3PN 6

CLASS 4PN 10

CLASS 5PN 16

16 1.2 0.090

20 1.5 0.137

25 1.5 0.174 1.9 0.212

32 1.8 0.264 2.4 0.342

40 1.8 0.334 1.9 0.350 3.0 0.525

50 1.8 0.422 2.4 0.552 3.7 0.809

63 1.9 0.562 3.0 0.854 4.7 1.29

75 1.8 0.642 2.2 0.782 3.6 1.22 5.6 1.82

90 1.8 0.774 2.7 1.13 4.3 1.75 6.7 2.61

110 2.2 1.16 3.2 1.64 5.3 2.61 8.2 3.90

125 2.5 1.48 3.7 2.13 6.0 3.34 9.3 5.01

140 2.8 1.84 4.1 2.65 6.7 4.18 10.4 6.27

160 3.2 2.41 4.7 3.44 7.7 5.47 11.9 8.17

200 4.0 3.70 5.9 5.37 9.6 8.51 14.9 12.8

225 4.5 4.70 6.6 6.76 10.8 10.8 16.7 16.1

250 4.9 5.65 7.3 8.31 11.9 13.2 18.6 19.9

280 5.5 7.11 8.2 10.4 13.4 16.6 20.8 24.9

315 6.2 9.02 9.2 13.1 15.0 20.9 23.4 31.5

355 7.0 11.4 10.4 16.7 16.9 26.5 26.3 39.9

400 7.9 14.5 11.7 21.1 19.1 33.7 29.7 50.8

450 8.9 18.3 13.2 26.8 21.5 42.7 - -

500 9.8 22.4 14.6 32.9 23.9 52.6 - -

560 11.0 28.1 16.4 41.4 26.7 65.8 - -

630 12.4 35.7 18.4 52.2 30.0 83.2 - -

710 14.0 45.3 20.7 66.1 - - - -

Notes : 4.1 : Nominal pressure (PN) in BAR, Nominal outside diameter and nominal wall thickness are based on overall service (design) Coefficient of C = 2.5 4.2 : Shaded sizes and class are only manufactured on special request. 4.3: 1 BAR = 0,1 MPa = 0,1N/mm2 = 100 kPa = 14.5 psi = 1,02 kg/cm2 = 0,987 atm = 10 meterhead water 4.4: 1 meter,m= 39.37 in = 3.281 ft = 100 cm = 1000 mm = 1.094 yd = 0.001 km 4.5: Colour : Grey8

PressurePipes for PotableWater Supply

TABLE 5 : DIMENSIONS BASED ON SSA 14, DIN 8062

SAPPCO DAMMAM UPVC pipe is produced from specific pipe grade suspension PVC homopolymer and only recommended additives are added to give optimize processing and generate desirable physical charateristics in the pipe.

Table 5 shows the range of UPVC pipes of two different pressure ratings 10 Bar and 16 Bar for potable water supply, irrigation or for any other under-pressure system. The pressure ratings indicated are the continuous working pressures at 20°C temperature for portable water.

NominalOutsideDiameter, mm

Class 4 (10 Bar)Nominal wallThickness, mm

Class 5 (16 Bar)Nominal WallThickness, mm

Working (Operating)Temperature

°C

°F

Derating FactorsSuitable at elevated temperature

16 20 25 32 40 50 63 75 90 110 140 160 225 280 315

- - 1.5 1.8 1.9 2.4 3.0 3.6 4.3 5.3 6.7 7.7 10.8 13.4 15.0

1.2 1.5 1.9 2.4 3.0 3.7 4.7 5.6 6.7 8.2 10.4 11.9 16.7 20.8 23.4

Notes : 5.1 : Nominal Pressure and wall thickness are based on Cefficient “C” 2.5 5.2 : Colour : Grey 5.3 : Specify joint, Rubber seal or solvent weld when ordering.

Notes : 7.1 : Classification is according to different standards based on metric systems dimensions 7.2 : Comparison is in relation to design Coefficient of C = 2.5 7.3 : Standard Dimension Ratio “SDR” = Outside dia / wall thickness

UPVC pipe is suitable for water application upto 60°C (140°F) and relationship between rec ommended maximum working pressures and various temperatures for pipes to ISO and DIN Standards is given in Table 6.

EFFECT OFELEVATEDTEMPERATURE

TABLE 6 : TEMPERATURE AND PRESSURE RELATIONSHIP

TABLE 7 : COMPARISON OF PIPE CLASSIFICATION SAPPCO CLASS

SDR CLASSIFICATION

Factor

20 30 35 40 45 50 55 60

68 86 95 104 113 122 131 140

1.00 0.90 0.80 0.70 0.64 0.44 0.33 0.26

Class 2 Class 3 Class 4 Class 5

PN 4 PN 6 PN 10 PN 16

2 3 4 5

2 3 4 5

20 16.7 10 6.3

- 16.7 10 6.3

SDR 51 SDR 34 SDR 21 SDR 13.5

ISO 161-1 Rating

SSA 14 Class

DIN 8062 Series

ISO 4422 Series

EN 1452 Series

9

Pipes for Soil,Waste dischargewithin buildingstructure

TABLE 8 : DIMENSIONS BASED ON DIN EN 1329-1 and ISO 3633

Table 8 shows the range of UPVC pipes in two types - Type B and Type BD for soil, waste discharge inside the buildings; Type BD is particularly suited for maximum service life with intermittent domestic hot and cold water discharge for inside buildings and buried within the building structure.

Pipe forundergroundDrainage andSewerage

Table 9 shows the range of UPVC pipes for below ground drainage and sewerage. SDR 34 (SN 8) being suited for maximum service life for the area under and within one meter from the building where pipes and fittings are buried in ground and are connected to the soil and waste discharge system and SDR 41 (SN 4) for the area more than one meter away from the building.

Nominal sizeDN / OD

Type : BNominal wallThickness, mm

Type : BDNominal WallThickness, mm

32 40 50 63 75 82 90 110 125 140 160 200 250 315

3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.2 3.2 3.2 3.2 - - -

- - - - 3.0 3.0 3.0 3.2 3.2 3.5 4.0 4.9 6.2 7.7

TABLE 9 : DIMENSIONS BASED ON DIN EN 1401-1 and ISO 4435Nominal sizeDN / OD

SDR 41 (SN 4)Nominal WallThickness, mm

SDR 34 (SN 8)Nominal WallThickness, mm

110 125 140 160 200 250 315 355 400 450 500 630 710

3.2 3.2 3.5 4.0 4.9 6.2 7.7 8.7 9.8 11.0 12.3 15.4 17.4

3.2 3.7 4.1 4.7 5.9 7.3 9.2 10.4 11.7 13.2 14.6 18.4 -

NOTES : 8.1 : EN 1329-1 identical to BS EN 1329-1 and DIN EN 1329-1 8.2 : EN 1329-1 replaces DIN 19531, BS 4514 8.3 : Type “B” used for inside building 8.4 : Type “BD” used for inside building and buried in ground within building structure 8.5 : DN/OD : nominal size to outside diameter related. 8.6 : Colour : Grey

Notes : 9.1 : EN 1401-1 identical to BS EN 1401-1 and DIN EN 1401-1 9.2 : EN 1401-1 replaces DIN 19537, BS 4660, BS 5481 9.3 : SN, ring stiffness of pipes expressed in KN/m2

9.4 : Sizes greater than 400 mm are only manufactured on special request 9.5 : DN/OD nominal size to outside diameter related. 9.6 : Colour, Grey or Golden Brown.

10

Hot waterdrainage

Surface Temperature dueto discharge of hot water

Theoretically pipes and fittings made from UPVC are unsuitable for use with very hot water and this is true for continuous flow at full bore. However, pioneering work carried out in Great Britain established design criteria that became adopted into their national standards. From this acceptance of UPVC drainage system, the Market grew until it now has far greater sales and use than any other above ground system and is rapidly following the same trend with below ground drains and sewers. The design criteria was verified and tested by development of a Hot & Cold Cycle Test and its principles have been adopted by many other National Standards Organisations, ISO, Government and Private Test Establishments.

The work carried out on UPVC drainage pipe work produced the following design criteria:

1. UPVC has natural insulating properties.

2. Each increment of wall thickness has its own insulating value thus the thicker the pipe the less transfer of heat through the wall thickness. So constant water flowing at 90°C will only produce a surface temperature of 60°C on the outside surface of a pipe with wall thickness 3.2 mm (See Fig. 2).

3. A discharge of short period for about 20-30 minutes will be necessary for the above transfer of heat to occur.

4. The softening point of UPVC plays an important role in the above situation.

Although the temperature of the inside wall of the pipe has exceeded the softening point, the external surface temperature is well below. Thus the pipe and fittings remain rigid and able to resist loadings imposed by expansion, contraction and soil pressures in the case of buried drains. Also, normal discharges, from the most powerful washing machines and domestic appliances will not harm UPVC Drainage Systems.

Similar tests have been devised for below ground applications, but using a lower discharge temperature to ensure that below ground drainage also meets the same service life expectancy.

The Combination of generous wall thicknessand high softening point provides safe limitsfor maximum service life.

External Surface,temperature notexceeding 60°C.

Fig 2

11

Electrical andTelecommunicationCable Conduit

TABLE 10 : DIMENSIONS BASED ON SSA 255 AND BS6099 : 2-2

Table 10 shows the UPVC pipes of different gauges - medium and heavy gauge - for use as electrical and telecommunication conduits. For consideration of pipes of other dimensions our Technical Sales Department may be consulted.

Cable duct pipes forTelecommunications and Elec trical Power Systems

Table 11 shows the range of UPVC pipes for use as underground electrical and telecommunication cable ducts including those passing underneath the roads-direct buried (DB) or encasement buried (EB). For consideration of pipes of other dimensions our Technical Sales Department may be consulted.

Nominal outside diameter, mm

Medium Gauge (MG)Nominal wall thickness, mm

Heavy Gauge (HG)Nominal wall thickness, mm

TABLE 11 : DIMENSIONS BASED ON DIN 16873, 16875, SSA 14NominalOutsideDiameter, mm

Class : EBNominal WallThickness, mm

Class : DBNominal wallThickness, mm

50 63 75 90 110* 125 140 160* 200 225

1.8 1.9 2.2 2.7 3.2* 3.7 4.1 4.7* 5.9 6.6

2.4 3.0 3.6 4.3 5.3* 6.0 6.7 7.7* 9.6 10.8

NOTES : 10.1 : SSA 255 Specifies medium gauge pipes upto 32mm 10.2 : Nominal outside diameter 38 mm is customers specified 10.3 : Colour; Grey or black, other colors on request 10.4 : Specify class like MG or HG of Conduit while ordering

NOTES : 11.1 : *Pipe conform to SEC specification 23 - SMSS -1 and Saudi Telephone (MOPTT) Specification MAT - ST 2201 11.2 : Specify Class EB or DB while ordering 11.3 : Specify the pipe joint while ordering 11.4 : Colour, Grey or Black 11.5 : Conduits and Ducts to American Standards, please refer to our catalogue “Publication P7”.

16 20 25 32 38 40 50

1.5 1.6 1.8 2.1 2.3 2.3 2.8

1.9 2.1 2.2 2.7 2.8 2.8 3.4

12

SAPPCO UPVC to British standards for various Applications

European standards (EN) replace the following British Standard and EN are having confirmed status of British standards as BS EN identification, relevant EN standards are identical to BS EN standard.

Our valued customers are requested to note the following facts:

1: BS 4660 replaced by BS EN 1401-1

2: BS 5481 replaced by BS EN 1401-1

Note B1 : For pipe dimensions please refer to table 9 on page 10

3 : BS 4514 replaced by BS EN 1329-1

Note B2 : For pipe dimensions please refer to table 8 on page 10

For any further inquiry please consult our technical sales Department.

13

Pipe Lengths andJoints

SAPPCO pipes are available in nominal total standard lengths of 6 meters. Other lengths can be supplied by arrangement.

SAPPCO pipes are supplied with various joint systems.

1 : Plain End / Chamfered end. (Fig. 4a)Plain Ended (P/E) pipe for use with separate Couplings; Ring Seal, Solvent (Adhesive) Weld or Special Fittings. Pipe can also be supplied with both ends chamfered (D/C) if requested, in lengths of 6 metres.

2 : Plain Solvent Weld joint (Fig. 4b)Plain socket (P/S) Solvent Weld Joints. Pipes are supplied with an integral plain socket preformed in our factory. They are jointed using the recommended solvent adhesive supplied by SAPPCO and using the techniques specified on Page 16, 17 and 18.

3 : Rubber ring seal joint (Fig. 4c)Rubber ring joints (R/J). Pipes are supplied with integral grooved socket at one end incorporating elastomeric sealing ring. SAPPCO manufacture the world wide known Anger joint system, the Anger joint sockets are made with locally wall thickened pipe. In these joints, the rubber ring seal is so designed that the sealing power increases with the rise in internal pressure in the pipeline. For jointing procedure refer to page 18.

1 : Coupling with / without registerCouplings with double ring seals or solvent weld joints are supplied by SAPPCO for jointing plain ended pipes or when pipes are cut and jointed to required length. These couplings may either be with register or without register, the latter type being used for repair or alteration work in the existing lines. For specific diamensions refer to page 34, Table 16.

2 : Special adaptor CouplingA range of special adaptor couplings are available for connecting UPVC pipe of different standards (e.g. 6” ASTM or BS UPVC pipe to 160mm O.D., SSA or DIN UPVC Pipe).

3 : Flange Adaptor SocketedFlange holes drilled according to customer’s requirements

Fig 4a(a) Plain End/Cham fered End

Fig 4b(b) Plain Socket Solvent Weld Joint

Fig 4c(c) Anger Joint

Couplings Fig 5a

Fig 5b

14

Handling andStorage

Fig 6

Unplasticised PVC pipes are strong but light, their specific gravity being approximately one-fifth of Cast Iron. As a result, these pipes are more easily handled than their metal counterparts. Reasonable care, however, should be used at all times, and when off loading, pipes should be lowered, not dropped to the ground.

Pipes should be given adequate support at all times. Pipes should not be stacked in large piles, especially in warm temperature conditions, as the lower layers may distort; resulting in difficulties in jointing and pipe alignment. Any pipe with ends prepared for jointing (socket and spigot joints, ‘A’ joints, etc) should be stacked in layers with sockets placed at alternate ends of the stack and with the sockets protruding to avoid unstable stacks and the possibility of imparting a permanent set to the pipes.

For long-term storage, pipe racks should provide continuous support, but if this is not possible, timber of at least 3in. (75mm) bearing width at spacings not greater than 3ft. (915mm) centres for pipe sizes 160mm and above, should be placed beneath the pipes and at 6ft. (1.8m) centres at the side, if the stacks are rectangular. These spacings apply to pipe size 160mm and above. Closer supports will be required for sizes below 160mm. In such pipe racks, pipes may be stored not more than seven layers, or 6ft. (1.8m) high, whichever is the lesser, but if different classes of pipe are kept in the same racks, then the thickest classes of largest diameter must always be placed at the bottom.

For temporary storage in the field, where racks are not provided, the ground should be level and free from loose stones. Pipes stored thus should not exceed three layers high and should be stacked to prevent movement.

Stack heights should be reduced if pipes are nested, i.e. pipes stored inside pipes of larger diameters. Reductions in height should be proportional to the weight of the nested pipe compared to the weight of the pipes normally contained in such stowages.

UPVC pipes should always be stored in the shade to avoid ultra-violet (U/V) degradation from the sun’s rays. Effect of UV Light refer to page 30 of this catalogue.

Since the soundness of any joint depends on the condition of the spigot and the socket, special care must be taken in transit, handling and storage to avoid damage to the ends.

When loading pipes on the vehicles, care must be taken to avoid their coming into contact with any sharp corners such as cope irons, loose nail-heads, etc., as pipes may be damaged by being rubbed against these during transit. Whilst in transit, pipes shall be well secured over their entire length and not allowed to project unsecured over the tailboard of the lorry. Pipes may be off-loaded from lorries by rolling them gently down timbers, care being take to ensure that pipes do not fall one upon another, nor on to any hard or uneven surfaces.

15

Site workInstructions

Cutting and Cham fering

Solvent WeldJoints

Jointing procedure

Pipe should be cut square. A simple method of cutting pipes square is to wrap newspaper or similar sheet paper around the pipe with no overlap of the edges. Mark line around pipe (felt pen is ideal). Cut to line with a fine toothed saw.

Pipe ends should be chamfered at an angle of approximately 15°C to about 1/3 of the wall thickness with a coarse file, Surform tool or chamfering tool.

Pipes up to 75mm may be jointed easily with solvent adhesives. Larger sizes required more special techniques and require two men to make such joints.

1. Mark depth of entry of the pipe into the socket and alignment mark.

2. Make small chamfer on the edge of the pipe end with medium file.

Fig 7a

Fig 7b

Fig 8

16

3 . Roughen the outside of the pipe and the inside of the socket using sandpaper or emery cloth upto the entry mark.

4 . Clean both surfaces and remove all dust, grease and swarf using a dry clean cloth and cleaner.

5. Stir solvent adhesive thoroughly. Use proper solvent adhesive.

6. Apply adhesive without delay after cleaning, using a flat clean and proper brush. Apply an even unbroken layer brushing axially to the pipe end and socket mouth with a heavier layer on the pipe. Where loose fits are found, the pipe should be given a second coat.

7. Immediately insert the pipe into the socket up to the entry mark, align pipe and socket. Hold in position for a few seconds, then wipe off excess cement.

8 . Solvent Weld Jointing of large diameter pipe requires special care. Use sufficient hand power to maintain proper alignment and to bottom pipe in socket / fitting.

9. Always replace the lid of the can after making a joint and follow the instructions on the can observing any warnings.

10. Always use the Solvent adhesive supplied and approved by SAPPCO or APLACO. TEST CONTENTS IN ACCORDANCE WITH INSTRUCTIONS ON EACH CAN.

11. Joints should not be moved or disturbed for initial set time depending on size. Then the jointed pipe may be handled with care. Allow 4 hours if the jointed pipe lengths are to be laid in a trench.

12. Allow 8 hours to elapse before applying working pressure or 24 hours for test pressures. With pipe sizes up to 50mm it is possible to reduce this time. Allow 1 hour for each 3.5 atmospheres of pressure.

13. Read the precautions for “Solven Weld Joints” on page18.

Cleaner and cements are extremely flammable and must not be stored or used near heat or open flame. Read all warnings on cleaner and cement cans.NOTE : All solvent-welded PVC pipeline systems should be filled and/or flushed with water immediately after installation and curing to remove all flammable cement vapors. Failure to flush a new line leaves a dangerous potential for inadvertment ignition of any residual cement vapors.

CAUTION

17

Precautions inmaking Solvent weld joints

Ring SealJoints

Jointing Clamps

Fig 9

Fig 10

Brushes must be clean and dry before commencing solvent welding. Brushes must be thoroughly cleaned after use by washing out in cleaning fluid.

Do not dilute solvent adhesive with cleaning fluid.

Use Solvent adhesive and cleaning fluid in a well ventilated area. Keep away from naked flames and do not smoke. Always replace lids of containers, in any event, attention is drawn to the instructions printed on the containers.

When laying continuous runs of pipe, joints may be made quicker than the setting times advised above. The joint will not be disturbed with long lengths, providing that the pipe is not twisted or the previously made joint lifted out of place.

Ensure that the spigot and socket are free from dust, grit, grease and as dry as possible.

Insert pipe into the socket without seal ring in place and mark pipe when it is fully inserted.

Place seal in groove of socket ensuring that seal is correct way round. Rubber seal rings should be fitted with tapered section facing the outside of the socket.

Apply jointing lubricant to the chamfer and the end of the spigot of the pipe or fitting only.

Push the pipe firmly into the socket up to the insertion mark previously made. If an expansion gap is required the pipe is then pulled back by the desired amount. See Fig. 13 on page 21.

Jointing Clamps may be used for ease of assembly. The Clamps are available in two sizes, one for pipes 90mm to 160mm O.D. and the other for 225mm to 315 mm O.D. (See Fig. 10).

18

Rubber seal joint

Ring seal joints should not be used on above ground installations unless all the joints are anchored against end thrust.

UPVC Pipelines must be protected from direct sunlight and external heat, Please refer to page 30 “Effect of UV light”

Where plastic pipelines incorporate metal valves or other heavy fittings it is essential to support the valve directly rather than allow their weight to be carried by the plastic pipe.

For the same reason it is usually advisable to fix pipe supports on either side of flanged connections.

For light duty and small pipe sizes, plastic pipe support brackets are suitable. For heavier duty installations, matching formed metal pipe supports should be used with cork or P.E. liner for fixed points.

Plastic pipelines need to be supported at specific intervals. These intervals will depend on the specific gravity of the material being conveyed, the temperatures of the liquid and the environment and the pipe wall thickness and type of plastic used. Some deflection may be allowed between brackets and at changes of direction. The average deflection between centres should be up to maximum of 2.5mm.

TABLE 12Pipe bracket spacing in the case of fluids with specific gravity = 1 as well as for gases.

Above GroundInstallationPressure Installations

Protection of Pipelines

Support of Fittings.Heavy Valves etc.

Pipe BracketSupport

Pipe BracketSpacing

Fig 11

Examples of continuous support.

mm 20°C 30°C 40°C 50°C 16 75 60 40 Continuous 10 85 70 50 Continuous 25 90 75 55 45 32 100 85 65 50 40 110 100 80 60 50 125 115 95 70 63 140 130 110 85 75 150 140 120 95 90 165 155 135 105 110 185 175 155 120 140 215 205 185 160 160 225 215 200 170 200 240 225 215 185 225 250 240 225 200 250 260 250 240 205 280 270 260 250 215 315 280 270 260 225 355 290 275 265 230 400 300 280 270 235

Pipe support centres L in CM at:—dUPVC Pipes

Class4 and 5

Class3 should

bereducedby 10%

Class5 may

beincreasedby 10%

For vertical installations, the above support distances may be increased by 30% (Multiply the values given by 1.3)

For fluids with a specific gravity S.G. Factorexceeding 1 multiply by the 1.25 0.90factors shown 1.50 0.83 1.75 0.77 2.00 0.70 19

Pipe Supports—Loose and FixedArrangements

Axial movement of the pipe line must not be prevented, loose brackets or sliding points allow the pipe to move or slide as expansion or contraction taken place.

Fig 12a

To ensure that this movement is controlled it is necessary to create fixed points. Fixed points may be positioned at one end of a pipe run, at bends or changes of direction or in the centre of a pipe run.

Fig 12b

A fixed point may be created in pipeline by solvent welding two split collars on to the pipe. The collars should be positioned and clamped for 12 hours. Collars may be manufactured from pipe, a section of approximately 1/3 of circumference removed.

Fig 12c

Fig 12d

20

Below GroundInstallation

General Notes

A. As with all pipe jointing, cleanliness is of prime importance, and pipes, specially spigot ends, should be supported clear of the ground to prevent dirt being smeared on with the lubricant. Placing the pipes on blocks also reduces friction and consequently facilitates the making of the joint. THESE BLOCKS MUST BE REMOVED BEFORE BACKFILLING, AND EVERY CARE MUST BE TAKEN TO ENSURE THAT THE PIPE IS NOT BEDDED ON SUBMERGED ROCK.

B. The pipeline should be tested initially after a few joints (certainly not more than 500 metres) to ensure that they have been made correctly, and subsequently at convenient intervals, preferably not exceeding 1000 metres.

C. All changes of direction must be anchored. (See Fig. 14b.) Concrete thrust blocks are suitable but the unit should only be haunched and a flexible membrane interposed between the concrete and the unit, to protect it against damage by abrasion.

D. Before testing, the line must be backfilled leaving the joints exposed. If the joints must be covered, it is useful to mark their position.

E. The pipe should be marked so that the spigot enters the socket to within 13 to 25mm of the bottom of the socket dimension. The depth of chamfer should be one third the wall thickness.

F. Never cut the leg of a Ring Seal Joint bend. Some distortion of the shape may occur during processing which might cause a leak.

G. If jointing above ground, observe the depth of entry after installation.

H. UPVC Pipes may be cold flexed to accommodate ground contours and road curvatures in outside diameters up to 225mm. The bending radius (R) should not be less than approximately 300 times the outside diameter of the pipe (in mm). The cold bending and supporting is illustrated in Fig. 14a, for standard pipe length of 6 metres.

Pipes larger than 225mm diameter should be regarded as rigid and changes in direction should be accommodated by the use of special bends of flexible couplings.

Fig 13 Expansion Gap

13 to 25mm

21

Cold flexing inthe trench

Support

Laying

Excavation

Stone free tampered soil in order to prevent the spigot from being angled in the socket when bending the pipe.

It is very important when laying UPVC pipes for gravity drainage to ensure that the pipe is laid in accordance with the recommendations made on the following pages. These are extracted from the U.K. Ministry of Housing and Local Government’s Working Party report on the design and construction of underground sewers, but are equally applicable to pressure pipes.

The trench should not be opened too far in advance of pipe laying and should be backfilled as soon as possible. The width of the trench at the crown of the pipe should be as narrow as practicable but not less than the outside diameter of the pipe plus 300mm to allow proper compaction of the sidefill, 225mm above the crown of the pipe, the trench may be any convenient width. The inherent flexibility of UPVC drainage pipe can be used to advantage but care must be taken to ensure that the bed of the trench will support the pipeline adequately so as to prevent localised loss of gradient or bridging. Projections must be removed to avoid point loading of the pipe.

22

Fig 14a

TABLE 13Outside

Diameter

mm m m

Radius“R”

Elasticity“A” in 6m pipe

63 18.9 0.94

75 22.5 0.80

90 27.0 0.66

110 33.0 0.54

125 37.0 0.50

140 42.0 0.43

160 48.0 0.38

200 56.0 0.31

225 67.5 0.27

250 75.0 0.25

280 84.0 0.22

315 94.5 0.19

355 108.0 0.17

400 122.0 0.15

Typical arrangement of anchor blocksused in conjunction with UPVCpipe-work incorporating rubber ringmechanial joints when buried.

Fig 14b

23

Material for Beddingand Sidefilling

Bedding andSlidefilling

Backfilling

Some soils, as excavated from the trench (such as free drainage coarse sand, gravel, loam and soil of a friable nature) may be suitable for use as sidefill material, but they must be capable of being compacted sufficiently to provide adequate support for the pipe (see note following for test for suitability). Soils such as hard chalk which break up when wet, and clay should not be used immediately around the pipe for bedding, sidefill or backfill, unless a rotary type excavator has been used. Should the material excavated form the trench be unsuitable, then a backfill medium, which complies with U.K.B.R.S. tests described at the end of this section must be used. Granular material is very satisfactory as it requires little compaction once placed, but any material which complies with the U.K.B.R.S recommendations is suitable.

With flexible pipes it is of great importance that the sidefill should be very firmly compacted between the sides of the pipe and the soil sides of the trench. Any trench sheeting should be partially withdrawn to allow this to be done.

Before backfilling, any levelling pegs or temporary packing should be removed. The thickness of the bedding under the barrel of the pipe should be not less than 1/3 of the diameter, and a minimum of 100mm thick. In very soft or wet conditions, or where the bottom of the trench is very irregular, this thickness should be increased as necessary to give a suitable bed.

The bedding should be thoroughly compacted in layers not more than 150mm thick to give a uniform bed, true to gradient, on which the pipe may be laid. Pipes should be laid directly on this bedding. Bricks or other hard materials must not be placed under the pipes for temporary support. Further bedding material should be placed around the pipe and be thoroughly compacted in 75mm layers by careful tamping up to the crown of the pipe, eliminating all cavities under the two lower quadrants of the pipe.

The same material should then be placed over the crown of the pipe for not less than 2/3 or the diameter, with a minimum height of 100 mm and a maximum of 300 mm and be thoroughly compacted. The Process of filling and tamping should proceed equally on either side of the pipe, so as to maintain an equal pressure on both sides.

Normal filling of the trench should then proceed in layers not exceeding 300mm in thickness, each layer being well rammed. Heavy mechanical rammers should not be used until the fill has reached a depth of 300mm above the top of the pipe. Special consideration and selection of back filling material will be necessary if the risk of surface subsidence is an important consideration, for example under roads.

24

Examples of Trenchpreparation andBackfilling

Fig 15a

25

Trench Preparation

Fig 15bCompacting Layers of Backfill –(Even tamping in 75mm layers upto top of clean cut trench.)

Fig 15cNormal Filling — (Layers of 300mmtamped by non-mechanicalrammers), Until over 300mm fromlevel has been reached.

When pipe lines are layed in hot climatic conditions it is advisable to fill the pipe with cold water to bring the pipe lengths to normalcontracted dimension. Check the joints in the case of dry jointed or ring sealjoints to ensure that socket insertion depth is satisfactory.

Special Cases

Maximum AllowableDeformation

Test for the suitabilityof Soil Material forsurrounding FlexibleSewer and Drain Pipes laid Underground

Fig. 16

For special cases of unstable ground and areas of mining subsidence where “draw” of the joints may be expected, telescopic joints should be used throughout the line, though most flexible pipes are capable of following any ground movement of normal degree without fracture of failure.

For the necessary reaction from the sidefill to develop, it is necessary for some deformation or ovality of the pipe to take place. Until more is known on the subject, the United Kingdom Building Research Station consider that the maximum acceptable decrease in vertical diameter is 5%, because above this figure there is a risk of blockage, leakage from joints or collapse of the pipes.

(a) PARTICLE SIZEThe maximum particle size should generally not exceed 20mm. The presence of an occasional particle between 20mm and 40mm is acceptable provided the total quantity of such particles is only a very small fraction of the whole. If particles over 40mm are present the material should be rejected. In cases of doubt, a weighed representative* sample of material - about 2kg - should be sieved** using 20mm and 40mm sieves. If any particles are retained on the 40mm sieve, the material is not acceptable unless it is first screened so as to comply with this requirement.

(b) EASE OF COMPACTION - Apparatus required.

1. Open-ended cylinder 250mm long and 150mm ± 6mm internal diameter, (160mm Class 3 Sappco UPVC pipe is suitable).

2. Metal rammer with striking 40mm diameter and weighing 1 to 1.25 kg.

3. Rule.

Obtain a representative sample more than sufficient to fill the cylinder (about 11.5kg) it is important that the moisture content of the sample should not differ materially from that of the trench. Place the cylinder on a firm flat surface and gently pour the sample material into it, loosely and without tamping. Strike off the top surface level with the top of the cylinder and remove all surplus spilled material. Lift the cylinder up clear of its contents and place on a fresh area of flat surface. Place about 1/4 of the material back in the cylinder and tamp vigorously until no further compaction can be obtained. Repeat with the second quarter, tamping as before, and so on for the third and fourth quarters, tamping the final surface as level as possible.

Measure down from the top of the cylinder to the surface of the compacted material. This distance in mms divided by the height of the cylinder (250mm) is referred to as the Compaction Fraction.

26

Notes

Compaction Fraction —Suitability for use

Maximum andminimum coverdepths

27

U.K. Ministry of Housing and Local Government Working Party of the Design and Construction of Underground Sewers’ first interim report. H.M.S.O. 1966.

* To obtain a representative sample, about 50kg of the material should be heaped on a clean surface and divided with the spade down the middle into two halves. One of these should then be similarly divided and so on, until the required weight of sample is left.

** In the sieving, clumps of material that break up under light finger pressure may be helped through the sieve, but considerable force must not be used to squeeze oversize clumps through the mesh.

0.1 or less (25mm) — Material suitable0.1 or 0.3 (25mm to — Material suitable but requires extra care 75mm) in compaction. Not suitable if the pipe is subject to waterlogged conditions after laying.Over 0.3 (75mm) — Material unsuitable.

Whether under roads and verges or in open country, UPVC pipes may be buried with a maximum cover depth of 6.1 metres.

However, a minimum cover depth of 1.2 metres should be allowed when pipes are installed under roads. Tests have shown that traffic loads (wheel loads) do not affect pipes with this amount of cover depth provided they are properly installed and back-filled. At depths less than 1.2 metres, special consideration should be given to all the engineering factors involved, such as class of road, its construction and the position of other services. Under these circumstances, concrete may be used as a protecting raft above the pipeline, provided a cushion of fill is laid between the pipe crown and the raft.

In open country, where top loading is unlikely to occur, pipes may be laid with a minimum cover depth of 0.45 metres without any protection. At depths less than 0.45 metres, elsewhere than under roads, concrete slabs on a cushion of fill materials above the pipe should be used as a protection against picks, gardening implements, etc.

Fig 17

Soil Loading(non Pressure)

Because UPVC pipes are an inherently flexible material, results obtained from a crushing test such as that carried out on conventional rigid materials give figures that in no way relate to the performance of the pipe under trench conditions. A rigid material such as cast iron, cement asbestos or salt glazed pipe, when subjected to a compressive load will show virtually no sign of deformation. it is possible to increase the load until a point is reached where the pipe will fail without further noticeable deformation. Similar tests carried out on UPVC pipes cause deformation at a relatively low load. Any increase in the load causes the pipe to be considerably deformed although removal of the load allows the pipe to return almost to its original shape. To get a true picture of UPVC drainage pipe performance, tests have been devised by the U.K. Agreement board, the U.K Building Research Station and The British Plastics Federation, to simulate ground conditions. All tests are conducted on the basis that 5% is the maximum allowable deformation.

110mm and 160mm domestic drainage pipes are subjected to a maximum temperature of 86°C for short periods. They are therefore subjected to hot and cold water discharges over 2,500 cycles to represent statistically a 50-year usage. During the cycling period a load of 8,000 Ibs per square foot (3628.7kg per .092sqm) is applied to the pipe backfill approximately 2 ft. (.609m) above the crown of the pipe. Pipes above 160mm diameter are not subject to such a high elevated temperature. Tests on larger diameter pipes have therefore been conducted assuming continuous discharge at lower temperatures. Once again a static load is applied continuously and on pipe sizes above 160mm is 9000 Ibs (4082.3 Kg) for 200mm and 250mm, and 315mm 10,000 Ibs (4535.9 Kg).

In the design of pipe the U.K. Ministry of Housing and Local Government Working Party has recommended that pipes laid under fields, etc., should be designed to support two wheeled loads each of 7,000 Ibs. (3175.1 Kg) each, spaced 3 ft. (.914m) apart, with an impact factor of 2 in addition to the weight of the backfill. For pipes laid under roads carrying traffic, the two wheel loads should be 16,000 Ibs. (7257.4 Kg) each, spaced 3 ft. (.914m) apart, with an impact factor of 1.5. The effect of surface loading diminishes with depth and theory indicates that for a 110mm pipe at 3 ft. (.914m) a static load of 2 by 16,000 Ibs (7257.4 Kg) would produce only slightly more effect than that of 2 by 7,000 Ibs. at 2 ft. (3175.1 Kg at .609m). Also, it is the proportion of the pipe vertically below one wheel that is mainly affected. The contributory effect of the second wheel 3 ft. (.914m) away adds only 5% extra at 3 ft. (.914m) and 10% extra at 2 ft. (.609m). The effect of increasing pipe diameter increases the projected area of the pipe subjected to load to a maximum of 10,000 Ibs. (4535.9 Kg.) Therefore on 110mm pipe the load is 8,000 Ibs. (3628.7 Kg), 160mm pipe 8,000 Ibs. (3628.7 Kg) and above this size as quoted above. These tests are designed to simulate the worst possible operating conditions but notwithstanding this, the maximum deformation of 5% is still not exceeded. Work is continuing in this field both on a practical and theoretical basis by the plastics industry as a whole, with a view to giving engineers further information on the design aspects of UPVC drainage pipe.28

Hydraulic Testingof Pipeline

Important Notes

29

The pressure testing of pipeline shall be conducted with water at interval initially not exceeding 500 meters and subsequently not exceeding 1000 meters. Pipe should be adequately anchored to prevent movement. The joint and the pipeline should be slowly filled with clean water taking care to prevent surge and air entrapement. All entrapped air must be purged from the line before applying pressure. All air release valves should be installed at high points and a further precaution against air entrapement is to pass a foam swab through the pipe line. The passage of foam swab will additionally clean the line of any debris left in the line during laying.

The temperature of test water should be preferably maximum 23°C. When testing above 23°C please use safety factor given in Table 6 of page 9 in this catalogue.

The test pressure and duration shall meet the requirements of local regulations where applicable.

The line should be pressurised to 1.5 times of the System Design Operating Pressure but not less than 15 psi nor in excess of the pressure rating for pipe or appurtenances. Measure the pressure at the lowest elevation possible.

The duration of pressurization shall be preferably 1 hour but not to exceed 3 hours.

All visible leaks or any leak in excess of the permitted variation should be repaired and the pipeline retested following the same procedure.

1. Pipeline systems should be constructed to avoid excessive water hammer / surge pressure. (see details on page 30)

2. Air must be purged from pipelines before applying pressure3. Joint must be covered and protected from heat and UV resistance,

particularly in the mid day time.4. Allow 24 hours for line test pressure with pipe sizes upto 50mm it is

possible to reduce the time or 8 hours to elapse before working pressure.

5. PVC Non-pressure pipelines installed are tested to low pressures for a specific period of time (leakage tests).

6. In hot weather pressure test in early morning is recommended.

WARNING• NEVER use compressed air or gas in PVC

pipeline.• NEVER test PVC pipe and fittings with

compressed air or gas.• ONLY use PVC pipe for water and approved

chemicals.Use of compressed air or gas in PVC pipe and fittings can result in explosive failures and cause severe injury or death.

Water HammerConsiderations

Effects ofUltra-Violet (UV) Light

Surge pressures due to water hammer should be considered when designing a piping system. A momentary pressure rise occurs when liquid is started and stopped quickly, and is caused by the momentum of fluid. Pressure rise increases with the velocity of the liquid, the length of the piping system from the fluid source, or with an increase in the speed of starting or stopping. For example hydraulic shock occurs when valves are opened or closed quickly, or pumps are started with an empty pipeline.Proper design when laying out a piping system will eliminate the possibility of hydraulic shock damage. The following suggestions shall help to avoid the problems:1. In any piping system, including thermoplastic, a fluid velocity not exceeding 1.52m/sec. will minimize hydraulic shock effects, even with quick-closing valves.2. Using actuated valves with a specific closing time will reduce the possibility of inadvertent opening or closing of a valve too quickly. With pneumatic and air-spring actuators, it may be necessary to place a valve in the air line to slow down the valve operation cycle.3. Evaluate flow at pump start-up and during shut down. Also determine how much air, if any, is introduced during pump start-up.4. If possible, when starting a pump, partially close the valve in the discharge line to minimize the volume of liquid that is rapidly accelerated through the system. Once the pump is up to speed and the line completely full, the valve may be opened.5. Use surge control devices and standpipes wisely to give flow storage during surge. Check valves can be used near pumps to help keep lines full.6. Use properly sized vacuum breaker-air relief valves to control the amount of air that is admitted or exhausted throughout the system.For any further assistance do not hesitate to contact our Technical Sales Department.

UPVC pipeline systems when continuously exposed to ultraviolet (UV) radiation from sunlight, PVC pipe can suffer surface discoloration. This is commonly termed “UV degradation or sunburning,” colour change to brown due to UV attack.1. UV degradation or sunburning affects PVC when energy from the UV radiation causes excitation of the molecular bonds in the PVC. The resulting reaction occurs only on the exposed surface of the pipe and to extremely shallow depths of 0.025 to 0.076 mm. Degradation does not continue when exposure to sunlight is terminated. The study found that exposure to UV radiation results in a change in the pipe’s surface color and a reduction in impact strength. Other properties are not adversely affected.2. The most common method used to protect above-ground PVC pipe from the sun is painting with a latex (Water-based) paint. Preparation of the surface to be painted is very important. The pipe should be cleaned to remove moisture, dirt and oil, and then wiped with a clean, dry cloth. Petroleum-based solvents and paints should not be used, since the presence of petroleum will prevent proper bonding of paint to pipe.3. The color of the paint is of no particular importance. However, white color is recommended as it helps to reflect the sunlight.4. Burial of PVC pipe provides complete protection5. Pipe should be stored in the shade.

30

OrderingDetails

Abbreviations

31

To place an order, the following details should be provided for correct delivery of the material. Examples given below will clarify the order requirements.

DescriptionO.D. of the

required pipe Class of pipe Type of joint

Pipe 20 5 P/E Pipe 225 5 D/C Pipe 40 4 P/S Pipe 90 5 R/J Pipe 110 3 P/S Pipe 160 5 R/J Pipe 160 5 R/J Pipe 280 5 R/J Pipe 75 B R/J Pipe 110 BD PS Pipe 160 BD R/J Pipe 110 SDR 34 AJ Pipe 140 SDR 34 PS Pipe 250 SDR 41 AJ Pipe 400 SDR 34 LRJ Pipe 25 MG P/E Pipe 40 HG P/E Pipe 63 DB PS Pipe 110 DB PS Pipe 160 EB PS Coupling 90 4 R/J Coupling 160 2 P/S Bend 90° 50 3 P/S Bend 22 1/2° 225 5 R/J

SSA : (previously SAS) Saudi Arabian Standard OrganizationDIN : Deutches Institute für Normung (German)EN : European Norms (Standards)ISO : International Organization for StandardizationSN : Nominal Ring StiffnessSDR : Standard Dimension RatioPN : Pressure NominalEB : Encased buried in concreteDB : Direct buriedOD : Outside diameterMG : Medium GaugeHG : Heavy GaugeP/E : Plain Ended PipeD/C : Double Chamfered PipeP/S : Plain / Parallel SocketR/J : Rubber JointB/BD : Application area codes

FabricatedDrawn Radius Bends(Solvent Weld Joint)

32

Drawn Radius Bends are produced from normal wall thickness pipe.

PipeO.D. mm

Radiusmm

11 1/4°L.mm

22 1/2°L.mm

45°L.mm

90°L.mm

TABLE 14 :

Dimensions stated above are indicative. Detailed specification for design purposes should be obtained from our Technical Sales Department. Bends for sizes 250mm and above with solvent weld joint consult our Sales Department.

16 56 100 115 126 170

20 70 100 115 135 170

25 88 100 115 145 180

32 112 100 115 150 190

40 140 110 125 170 220

50 175 175 180 225 350

63 221 240 260 300 420

75 263 260 285 350 470

90 315 350 390 480 600

110 385 370 400 500 690

140 490 390 410 570 760

160 560 400 420 600 1000

200 712 480 540 760 1150

225 788 590 610 840 1240

Fig. 18a

Fig. 18b

Single Socketor Double Socketto be specified.

Single Socketor Double socketto be specified.

33

FabricatedDrawn Radius Bends(Rubber Seal Ring Joint)

TABLE 15 :Drawn Radius Bends are produced from Thickened pipe.

Fig. 19a

Fig. 19b

PipeO.D. mm

Radiusmm

11 1/4°L.mm

22 1/2°L.mm

45°L.mm

90°L.mm

Note : Bends of other Angles or radius to special order.

Dimensions stated above are indicative. Detailed specification fordesign purpose should be obtained from our TechnicalSales Department.

63 221 240 ” ” 260 ” ” 300 ” ” 420 75 263 260 ” ” 285 ” ” 350 ” ” 470 90 315 350 ” ” 390 ” ” 480 ” ” 600 110 385 370 ” ” 400 ” ” 500 ” ” 600 140 490 390 ” ” 410 ” ” 570 ” ” 760 160 560 400 ” ” 420 ” ” 600 ” ” 1000 200 712 480 ” ” 540 ” ” 760 ” ” 1150 225 788 590 ” ” 610 ” ” 840 ” ” 1240 250 852 680 ” ” 730 ” ” 850 ” ” 1350 280 980 700 ” ” 830 ” ” 1040 ” ” 1610 315 1103 810 ” ” 910 ” ” 1050 ” ” 1690

FabricatedCouplings

34

PipeO.D. mm L.mm L.mmT.mm T.mmD.mm

TABLE 16 :

Dimensions stated above are indicative, Detailed specification for design purposes should be obtained from our Technical Sales Department.

Fig. 20a

Fig. 20b

Fig. 20c

Fig. 20d

Dimensions for Couplings

R/J Coupling P/S Coupling

16 56 25

20 58 27

25 66 30

32 74 34

40 94 39

50 96 45

63 240 90 100 126 53

75 250 105 103 140 60

90 270 125 111 160 69

110 290 150 116 185 81

140 330 192 125 230 99

160 350 211 135 250 111

200 375 247 144 300 135

225 430 290 154 360 150

250 445 310 162 380 165

280 495 360 172 425 183

315 545 403 185 478 204

355 568 434 194 520 224

400 612 485 205 570 246

35

Cement andCleaner

Spare RubberSeal Rings(Elastomeric seals)

Quantities of solvent cement and cleaner required for sol vent cement jointing of UPVC pipes

Table 17 lists the approximate quantity of cleaner and sol vent cement needed to make solvent weld joints. SAPPCO rec ommended solvent cement is available in 1.0 Kg tins.The cleaner is available in one litre tins.

NOTE 17.1 : Solvent Cement Conform to ASTM D2564 or BS 4346-3 or equal 17.2 : Check date of expiry on the Can 17.3 : All Values stated are indicative

SAPPCO - DAMMAM supply rubber seal rings conforming to any one of the standards ISO 4633, BS 2494 or ASTM F477SAPPCO - DAMMAM supplied rubber seal rings are suitable for use with drinking water.

NOTES 18.1 : SAPPCO - DAMMAM reserves the right to supply 3S rubber seal ring or KW rubber seal ring for Anger joint (A/J) System. 18.2 : Rubber Seal ring must be protected from direct sunshine on job site.

SAPPCO Supplied Lubricant has been specially formulated for use on PVC pipes to facilitate the positioning of the Rubber Seal Rings joints. It is specially suitable for use on drinking (potable) water and meets the health regulations. Oil must not be used as lubricant.

Read the directions for use on the can.

TABLE 17 : Quantity of Solvent Cement and Cleaner to make jointsPipe diameter, mm

Quantity for Cleaner, Liters

100 joints Cement, Liters

No. of joints / Tin Size, Liters

16 20 25 32 40 50 63 75 90 110 125 140 160 200 225

0.09 0.18 0.30 0.50 0.70 0.90 1.10 1.30 1.40 1.70 1.90 2.10 2.50 4.50 4.50

0.25 0.40 0.55 0.80 1.10 1.50 1.70 2.20 4.00 8.00 10.50 13.00 19.00 26.00 26.00

432 260 185 125 90 60 58 45 25 12 9 7 5 4 3

TABLE 18 : Rubber Seal Rings Systems for SAPPCO pipe

System

Lubricant

3S Ringfor A/J

KW Ringfor A/J

Locking Ringfor Lock R/J

Lens Ringfor LR/J

Figure

Pipe size 63-500 mm 63-500 mm 355 mm 400 mm

SAPPCOLUBRICANT

Major Project usedSAPPCO UPVC pipe

36

1) Ministry of P.T.T. Saulitel Com. Various Project

2) Ministry of Water & Electricity

3) Ministry of Education Project

4) Ministry of Saudi Aramco Project

5) Royal Commission for Jubail and Yanbu

6) Sceco Project

7) King Abdullah City

8) King Abdulla University

9) Holding Hole in Alhasa and Hafr Al Baten

10) Sara Housing Project in Azizyah

11) King Fahd Causeway to Bahrain

12) Saudi Cement Expansion Plant in Al-Hasa

13) Doha International Airport Doha - Qatar

14) Water and Sewage Dept. WSD - Sana’s - Yemen

15) Adnoc - Abu Dhabi - UAE

16) Ministry of Health Hospital Projects

Quality ManagementSystem (QMS)

CustomerSatisfaction

SAPPCO DAMMAM FACTORY has established and applies a upgraded Quality Management System (QMS) and is certified in accordance with ISO 9001 the highest standard of quality system and excellence.

Our products meet the requirements of the relevant national and international standards.

SAPPCO control the entire manufacturing process from raw material to pipe and fabricated fittings.

Routine testing of all pipes produced at our factory is carried out as laid down in the relevant Standards in our well equipped laboratory. Inspection of pipes produced on each machine is carried out “round the clock” to make sure that exact standard pipe is delivered to our customers.

Periodically, SAPPCO - DAMMAM pipes are audit tested and evaluated by world renowned and accredited Test Centres as indicated below.

SAPPCO’s most important objective “Customer Satisfaction” is achieved with the comprehensive provision of high-quality products and services. As a leader in the plastic pipe industry.

SAPPCO DAMMAM FACTORY :

• Continually develope/manufacture new products.

• Modernize manufacturing extrusion system equipments.

• The quality management system (QMS) is characterized by a certified

and upgraded QMS to ISO 9001:2008

• In addition, our well experienced staff offers extensive industry

knowledge and field experience with thermoplastic piping products to

the customers.

• Continuous evaluation and improvement of the process.

• Customer satisfaction is SAPPCO’s top objective.

Our experience gained over the last 30 years is at the disposal of the customers.

37SAPPCO AND QUALITY RUN TOGETHER

UPVC PIPES AND FITTINGS

SAPPCO DAMMAM FACTORYBranch of Saudi Plastic Products Co. Ltd.C.R. 2050050912

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SAPPCO

SAPPCO after Sales ServiceProvides its customers with advice on any

technical problems they may encounter

For further details and information, contact

SAPPCO DAMMAM FACTORYFACTORY & MAIN OFFICES

FIRST DAMMAM INDUSTRIAL ESTATE - 8TH STREETP.O. Box 4916, Dammam 31412, Saudi Arabia

Telephone : (03) 847-1703 / 847-3323Telefax : (03) 847-1969

Key facts you should know about SAPPCO UPVC pipe

It’s costing less. While the cost of almost everything else has been going up, the cost ofUPVC pipe has been decreasing.

It’s easy to handle Because of it’s light weight and lack of fragility. It needs fewer men to handle it quicker.

It has a smooth boreWhich means betterflow characteristicsand no buildupof corrosionproducts.

It’s simple to joiningWith its integral push-fitself sealing action.Long runsof UPVC pressure pipe can be installed in record time.

It’s corrosion free.UPVC pipe just does not

corrode; it’s impervious toattack from aggressive soils,

water and most commonacids and alkalis.

Publication P.3, Issue 5March - 2009

SAPPCO UPVCpipe is suitable

for workingpressure up to

16 barat 20°C.

SAPPCO THE LEADING MANUFACTURER OF PLASTIC PIPES

SAPPCO THE LEADING NATIONAL FACTORY FOR UPVC PIPES

e-mail: sapdam@sappco.com.sa/info@sappco-dammam.com

RIYADH OFFICE : P.O. Box 2828, Riyadh 11461, Tel.: (01) 4480448 - Fax : (01) 4461392JEDDAH OFFICE : P.O. Box 5448, Jeddah 21422, Tel.: (02) 6749402, 6726318 - Fax : (02) 674 7827

Every care is taken to see that information given in this catalogue is correct and current but it is not intended to form\any part of any contract; and no warranty is intended to be given or implied in respect of the contents hereof.

Web site : http//:www.sappco-dammam.com

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