Handling, Storage and Installation Guidelines

HANDLING, STORAGE AND INSTALLATION GUIDELINES
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1. Handling and Storage ABS pipes and fittings shall not be subject to rough handling particularly during loading and unloading. Where ropes or chains are employed, pipes shall be suitably protected against scoring. The maximum storage height shall not exceed 1.5m. If different classes of pipe are kept in the same stack, the pipes of the highest class shall always be at the bottom. All pipes and fittings must be sheltered from sunlight. Elevated temperature may soften the pipes and may result in bowing and snaking.
2. Jointing Methods 2.1 Solvent Cement Joints Please refer to our catalogue for joining procedures. No. of coat of solvent cement and holding time are shown in Table 1 and Table 2 respectively. Table 1 Pipe Size < DN 50 DN 50 Coat Required Socket 1 1
Pipe 1 2
Pipe Size DN 15 DN 50 DN 65 DN 100 DN 150 DN 500
Table 2 Holding Time 10 60 sec. 1 5 min. Restrain with Monkey Wrench
Mark the pipe at a distance from the end which is equal to the fitting socket depth. This is to allow the installers to check whether the pipe is pushed fully home into the fitting. Immediately after application of the solvent cement push the pipe fully home into the fitting by using the mark on the pipe as a guide. Do not twist the fitting or the pipe. Only ABS solvent cement and ABS Primer from the same brand with ABS pipes and fittings are approved for joining. Manufacturers warranty will be null and void once other brand solvent cement or primer is used. ABS pipes and fittings cannot be successfully solvent cemented under wet conditions. Pipes and fittings must be clean and dry for effective joining. Other proper joining methods are as follows: Do not apply excessive solvent cement. Do not try to make the joint if the solvent cement has dried. Do not use primer to clean up excessive solvent cement. UPVC solvent cement and primer are strictly not allowed for use in joining ABS pipes and fittings. Do not thin solvent cement with primer. Do not use PAINT THINNER to replace primer or clean ABS pipes & fittings.
Copyright Azeeta Pipe System Sdn Bhd 2003
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2.2 Flanged Joints Full faced ABS socketed flanges and ABS socketed tub flanges shall be installed with loose metal backing rings All flange joints shall have a gasket or O-ring of appropriate material. Backing rings shall be of metal and protected against corrosion. Bolts must not be over tightened to such degree as to distort the ABS components of the piping system. 2.3 Threaded Joints ABS pipes and fittings may be joined by means of threaded connections, especially for connection of ABS pipes to pipes of other materials. Care should be taken not to over tighten or damage joints, and to provide adequate support to prevent excessive shear forces on threaded joints. A threaded joint made between ABS and metal, the ABS should be the male component of the joint.
3 Pipe Supports Recommended maximum spacing of horizontal pipe supports for ABS pipe at various temperatures are given in Table 3. Maximum spacing of vertical pipe supports is the same with that of horizontal pipe supports at 20C.
Table 3 Recommended Maximum Spacing of Supports for All Classes of Pipe Recommended Maximum Spacing of Support, (m) Horizontal or Graded Pipes Vertical Temperature Pipes 20C 50C 60C 0.9 0.7 0.4 0.9 1.0 0.7 0.6 1.0 1.0 0.85 0.7 1.0 1.2 0.9 0.7 1.2 1.2 1.0 0.7 1.2 1.3 1.0 0.7 1.3 1.6 1.3 0.9 1.6 1.9 1.5 1.0 1.9 2.1 1.8 1.0 2.1 2.4 1.9 1.2 2.4
Nominal Pipe Size DN 15 () DN 20 () DN 25 (1) DN 32 (1 ) DN 40 (1 ) DN 50 (2) DN 80 (3) DN 100 (4) DN 150 (6) DN 200 (8)
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Figure 1
Typical Vertical Pipe Support
Firm supports or anchoring points as depicted in Figure 2 shall be installed on vertical pipes at every five floors to prevent undue loading and stress being transmitted to the riser or dropper pipes.
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Figure 2
Typical Vertical Pipe Anchoring Point
Large valves, filters or other heavy items shall always be independently supported or anchored to prevent undue loading and stress being transmitted to the pipes. Valve support plates can be used in place of flange backing ring to provide necessary support.
Figure 3
Valves not independently supported
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Suspended Pipes The hanger type supports (wire, metal strip, etc.) as depicted in Figure 4 and 5 do not provide lateral restraint to the pipes and therefore encourage pendulous swinging and snaking which will in turn cause premature failures at fittings (especially tees and elbows). This shall, as far as possible, be avoided.
Figure 4
Figure 5
The correct pipe supporting is to allow controlled axial movement of the pipe while providing lateral restraint and adequate support for the pipe. The recommended way of installation is shown in Figure 6.
Figure 6
4 Exposure of ABS Pipes to Sunlight ABS pipes exposed to direct sunlight shall be painted with water based paint. Coating pipes with acrylic or water based paint is effective in minimizing any detrimental effects of ultraviolet radiation. ABS piping systems shall be installed to allow thermal movements where high temperature variations are likely to occur. The coefficient of thermal linear expansion () of ABS is 10.1 x 10-5 m/m C. Pipe expansion and contraction can be accommodated by the means of expansion arm and expansion loops. These methods are described below:
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Expansion Arm The change in length L of a pipe of length L when subjected to a temperature change T is L=L T where is the coefficient of thermal expansion of the pipe material. Minimum length of expansion arm (EA) in Figure 6 is given by the formula below:
EA( mm ) = 32.7 d L 32.7 = Constant coefficient of ABS d = Diameter of pipe (mm) L = Linear expansion (mm)
Figure 7
Expansion Loops
Figure 8
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All changes in direction of pipeline can be used to accommodate linear expansion. However, in some cases an expansion loop (Figure 7) is necessary e.g. in a long straight pipe run. Lengths of the expansion loop legs H for sizes up to diameter 110 are given in Table 4. Table 4 EXPANSION LOOP LEG LENGTH, H (mm) DN (mm) 15 20 25 32 40 50 65 80 100 150 25 635 735 820 925 1035 1160 1420 1465 1635 2005 50 900 1035 1160 1310 1465 1635 2005 2070 2315 2835 EXPANSION, L (mm) 75 1100 1270 1420 1605 1795 2005 2455 2535 2835 3470 100 1270 1465 1635 1850 2070 2315 2835 2925 3270 4005 150 1555 1795 2005 2270 2535 2835 3470 3585 4005 4905 200 1795 2070 2315 2620 2925 3270 4005 4140 4625 5665
All pipe clips shall permit free axial pipe movements at all temperatures and shall give good bearing support to the pipes. Care should be taken not to over-tighten the pipe clips. The mortar thrust blocks (Figure 8) are not recommended to be used as the supports of the ABS pipeline exposed to sunlight. This is because the thrust blocks restrain the pipes from expanding and contracting which will in turn cause the pipes to snake between thrust blocks and develop substantial longitudinal stress in the pipeline.
Figure 9
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5 Connection of ABS Pipes to HDPE Water Tank
The appropriate installation of ABS inlet pipe to HDPE tank in order to avoid any
unnecessary premature failure of the ABS pipe is depicted in Figure 9. The distance H can be obtained by using the formula given in Figure 10.
Figure 10
Recommended Way of Installation
Figure 11
Calculation of Distance H
Figure 11 shows the premature failures caused by the flexing of ABS inlet pipe which is induced by the flexing of HDPE tank wall. Figure 12 shows the installation without any bracketing.
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Figure 12
Flexing of ABS Inlet Pipe Induced by Flexing of HDPE Tank Wall
Figure 13 6 Connection to Hot Water Cylinder Supply For ABS pipe supplying cold water to a hot water cylinder, it shall not be used within a length of 1000mm from the connection to the cylinder (Figure 14). A non return valve shall be installed in the supply line between the cylinder and the ABS pipe.
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Figure 14 7 Temperature Considerations Where ABS pipes or fittings are under pressure and in continuous service at any temperature in the range from 20C to 60C, the safe working pressure shall be reduced in accordance with the values in Table 5. ABS pipelines must not be placed adjacent to sources of heat, e.g. furnaces, boilers or steam lines. If such a location cannot be avoided, suitable insulation and cladding should be provided to prevent the temperature of the pipe wall exceeding its design rating. Table 5 DESIGN LIFE YEARS 1 5 10 25 50 1 5 10 25 50 1 5 10 25 50 1 5 10 25 50 1 5 10 25 50 PIPE CLASS 6 9 12 WORKING PRESSURE, BAR 6.8 10.2 13.6 6.4 9.6 12.8 6.3 9.5 12.6 6.2 9.3 12.4 6.0 9.0 12.0 5.8 8.7 11.6 5.5 8.3 11.0 5.4 8.1 10.8 5.3 8.0 10.7 5.2 7.7 10.3 4.9 7.4 9.8 4.7 7.0 9.4 4.6 6.9 9.2 4.5 6.8 9.0 4.4 6.6 8.8 4.1 6.1 8.2 3.8 5.8 7.7 3.8 5.7 7.6 3.7 5.6 7.4 3.6 5.4 7.2 3.1 4.6 6.1 2.9 4.3 5.8 2.8 4.2 5.6 2.8 4.1 5.5 -
TEMP C
4.5 5.1 4.8 4.7 4.6 4.5 4.4 4.1 4.1 4.0 3.9 3.7 3.5 3.5 3.4 3.3 3.1 2.9 2.8 2.8 2.7 2.3 2.2 2.1 2.1 -
15 17.0 16.0 15.8 15.5 15.0 14.6 13.8 13.5 13.4 12.9 12.3 11.7 11.6 11.3 11.0 10.2 9.6 9.5 9.3 9.0 7.7 7.2 7.1 6.9 -
20
30
40
50
60
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8 Installation of the Pressure Reducing Valves Pressure reducing valves are recommended to be installed at every 5 floors or 25metres static height, in order to reduce the velocity of flow. The PRV must be mounted and supported to the wall. Make sure the pressure gauge is installed at the system as well (Figure 15).
Figure 15 9 Connection to Water Meters The water meter installed must be independently and firmly supported, in order to avoid any pre-mature failure on the pipes and fittings, due to stress caused by the weight of the meter and water. 10 Pump Selection A variable speed pump is recommended for plumbing installation. Please DO NOT use Hydro-Pneumatic Pumpset with Pressurestat control for the plumbing installation. 11 Hydrostatic Pressure Test The following are the requirements for pressure testing of all ABS pressure piping applications as set out in MS 1419: Part 4: 1998 Section 5: Pressure Testing.
i) Preparation for test

Air shall be removed by flushing or venting at the highest point. Pipelines shall not be tested to working pressure until at least 24 hours after the last joint has been made. Testing at pressures above working pressure shall not be performed until at least 48 hours after the last joint has been made.
ii) Test pressure, duration and temperature

A test pressure of 1.5 times the design pressure shall be applied to the section under test. The test section shall then be allowed to stand under pressure without make-up for at least 15 minutes, or the time necessary to inspect all joints in the completed section (12 hours maximum) at a temperature of 20C.
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iii) Acceptance criteria

A new pipeline shall be deemed to have passed the pressure test if there is no marked loss of test pressure and there is no evidence of leaks of the test fluid either after at least 15 minutes under pressure or after the time necessary to inspect all joints in the completed section (12 hours maximum).
CAUTION: Under no circumstances shall pressure tests be carried out by using pressurized gas. Such a test can be extremely dangerous.
12 Fatigue Failure and Water Hammer Fatigue Failure Repeated cyclic stressing of ABS plastics can cause a reduction in their strength through fatigue. Also, brittle like fracture at points of stress intensification is more likely under cyclic loads than under a simple static load. Regularly recurring surge pressures or pressure waves (resulted from quick closing flush valves and taps) will cause the pipes and fittings to undergo fatigue failure. Water Hammer Water hammer refers to fluctuations caused by a sudden increase or decrease in flow velocity. The pressure wave created is mainly dependant on the velocity of flow, the length of the pipeline and the closing time of the flush valve. Causes of Water Hammer in Internal Plumbing The primary cause of water hammer in internal plumbing is the quick closing flush valves and taps. Inappropriate pumps and control system supplied will also aggravate the problem. Use flow rate to control the pump operation is more appropriate than using pressurestat. Potential water hammer problems should be considered when pipeline design is evaluated and a thorough surge analysis should be undertaken, in many instances, to avoid costly malfunctions in a distribution system. Every major system design change or operation change, such as the demand for higher flow rates, should include consideration of potential water hammer problems. The following are some recommended measures to reduce the effects of water hammer: Prolong the flush valves closing time (adjusted to slow closure mode). Install water hammer arrestors, pressure relief valves, or surge tank whichever is applicable. Install variable speed pumps to cater for varying demands. Install correct sized pumpset with flow controlled operation as opposed to pressurestat controlled pumping system.
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Limitation of Liabilities
The information in these guidelines is provided in good faith but only for the purposes of general information and cannot be relied upon as a substitute for professional advice tailored to your particular circumstances. While Azeeta Pipe System Sdn Bhd has taken all reasonable efforts to ensure all information in these guidelines is accurate and reliable, it makes no representation or gives no warranty as to the accuracy, reliability or completeness of any information in these guidelines. Kindly refer to the MS1419:Part 4 (Guide for Installation of ABS Pipes System) for further details.

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HANDLING, STORAGE AND INSTALLATION GUIDELINES