TECHINICAL MANUAL

1.3 COMPARISION BETWEEN DIFFERENT PIPING SYSTEMS

S.N. PROPERTY/PARAMETER Galvanized Iron METAL PVC PPR-C
1. Service Life (Years) 5 - 15 10 - 30 10 >50
2. Standard Length (Meter) 6 5 6m 3-6
Hard or Soft Scolding Simple Thermal
3. Jointing Method Threaded Joint Solvent Cement
or Welding Joint Fusion
Requires Expert Expert Do it Do it
4. Skill
Plumber Plumber your self-basic skill Yourself
5. Jointing Time Few Hours Few Hours Few Minutes Few Seconds
Surface Surface Fusion of Material-
6. Strength of Joints Surface Homogeneity
Homogeneity Homogeneity Perfect Homogeneity
More than 4 More Than 4 Hrs/Half
7. Line Commissioning Time 24 Hours Immediate
Hrs/Half day Day
2 Persons 2 Persons 2 persons One Person
8. Minimum Labor
Required Required required Required
Depends on raw Depends on Raw
9. Water Absorption 0.15 0.03
material used Material Used
10. Brittleness Characteristics Resistant Resistant Poor-Resistance Highly Resistant
11. Corrosion Resistant Very Weak Weak Week Non Corrosive

12. Chemical Resistance Poor Average Average Excellent

13. Installation convenience Difficult Difficult Average Simple & convenient

14. Joining Reliability Good Average Very good Excellent

Unhygienic due to Food Grate-No

Solvent Cement is Leeches Chemically over
15. Hygienic Factor Zinc oxide Leeching-
Chemicaly Unsafe Service Time
Formation Bacteriology Neutral

Does not Retain Excellent

16. Inner Surface Smoothness Semi Smooth Semi Smooth
Smoothness Smoothness
Easiness in Repair &
17. Troubleness Difficult Difficult Very Easy
Maintenance
18. Wall Thickness OD 20mm 2.6mm 1.5mm 1.9mm 3.4mm
19. Water Freezing Inside Pipeline Bursts Bursts Bursts Does not Burst
100% Leak
20. Joint Leak Proffness Average-Leaks With Time Average Average Proof Entire Service
Life
Eco Friendly, No
High percentage of Harmful
21. Eco-Friendliness No No Chlorine & Toxic Substances
Gases in Case of Fire Produced During
Processing
1. Indoor & Outdoor installations 5. Drinking water transportation
of Hot & Cold water systems 12. Piping systems for transportation
2. Public Utility Pipelines 6. Liquid food transportation of aggressive fluids in industries

3. Industries such as Chemical 7. Pharmaceutical plants 13. Mining operations

plants, Breweries, Petroleum &
Gas plants, Oil plants, Mineral 8.
water plants, Water treatment
plants, Sugar Manufacturing
plants & other process industries
4. Residential & Commercial
Buildings ideal for concealed
piping system
4
Solar water heating systems
9. Heating system inside building
including floor, wall & radiator
heating
10. Air Conditioning system
11. Compressed air supply systems
14. Water treatment plants &
distribution network
15. Sewerage networks
16. Public places such as Hospitals,
Schools & Colleges, Hotels,
Cinemas, Airports, Railways, Bus
stations, Swimming pools etc.,
TECHINICAL MANUAL

2.0 PRODUCT CHARACTERISTICS

2.1.1 PHYSICAL PROPERTIES

PROPERTY TEST METHOD UNITS VALUE

o
Density, at 23 C ISO R 1183 g/cm 3
0.897
Melt Flow Index ISO R 1133
o
MFI 190 C/5Kg g/10min 0.50
o
MFI 230 C/2.16Kg g/10min 0.30
o
MFI 230 C/5Kg g/10min 1.30
Viscosity ISO 1191 cm3/g 420-430
ISO 1628 T3

2.1.2 THERMAL PROPERTIES

PROPERTY TEST METHOD UNITS VALUE
Thermal Conductivity DIN 52612 W/m.K 0.24
o
Specific heat, at 23 C Calorimeter KJ/Kg.K 2.0
o
Coefficient of linear expansion DIN 53752 mm/M C 1.5x10-4
o
VICAT Softening Point ISO 306 C 132
o
Melting Temperature Range ISO 3146 C 140-150

2.1.3 MECHANICAL PROPERTIES

PROPERTY TEST METHOD UNITS VALUE
Tensile Stress at Yield ISO 527-1,2 MPa 24
(50mm/minute)
Tensile Strain at Yield ISO 527-1,2 % 10
(50mm/minute
Tensile Modules (Secant) ISO 527-1,2 MPa 850
Flexural Modules ASTM D 790 MPa 850
Tear Strength ISO 527 MPa 40
Elongation at Tear ISO 527 % 800
Shore D Hardness DIN 53 505 - 65
Pipe Friction Factor - - 0.007
o
CHARPY Impact Strength 23 C
o
0C
o
-30 C

2.1.4 ELECTICAL PROPERTIES

PROPERTY TEST METHOD UNITS VALUE
Die Electric Constant DIN 53483 - 2.3
Volume Resistivity DIN 53482 Ohm-cm >1x1016
Die Electric Strength DIN 53481 Kv/mm 3
20

5
 TECHINICAL MANUAL

2.2 STANDARD WORKING CONDITIONS & SERVICE LIFE

Long-term performance curve show the behavior of pipe line ADMISSIBLE OPERATING PRESSURE
Pipe Serises according
depending on pressure & operating temperature. It establishes the

Temperature 0C
to DIN 8077/8078

Service Lite
average life expectancy of a pipe line as a function of hoop stress SDR 11 SDR 74 SDR 6

In Years
acting on the pipe walls. PN 10 PN 16 PN 20
Safety-factor 15
Nominal pressure for
Hoop stress is in proportion with the pressure according to the PP-R pipes (kgs/cm2)

following formula:- 1 17.6 27.8 35.0

5 16.6 26.4 33.2
0 C 10 16.1 25.5 32.1
δ = Sf X p X (d-s)/ 2s 10 25 15.6 24.7 31.1
50 15.2 24.0 30.3
100 14.8 23.4 29.5
Where: 1 15.0 23.8 30.0
5 14.1 22.3 28.1
0 C 10 13.7 21.7 27.3
δ = hoop stress (MPa) 20 25 13.3 21.1 26.5
50 12.9 20.4 25.7
100 12.5 19.8 24.9
Sf = Safety factor 1 12.8 20.2 25.5
5 12.0 19.0 23.9
p = Internal pressure (MPa) 0 C 10 11.6 18.3 23.1
30 25 11.2 17.7 22.3
50 10.9 17.3 21.8
d = Outside diameter of Pipe (mm) 100 10.6 16.9 21.2
1 10.1 17.1 21.5
S = Wall thickness of Pipe (mm) 5 10.1 16.0 20.2
0 C 10 9.8 15.6 19.6
40 25 9.4 15.0 18.8
If we extrapolate the hoop stress from the long term performance 50 9.2 14.5 18.3
100 8.9 14.1 17.8
curve and apply the formula using 1.5 safety factor, the admissible
1 9.2 14.5 18.3
operating pressure are obtained as given in the table. 5 8.5 13.5 17.0
0 C 10 8.2 13.1 16.5
50 25 8.0 12.6 15.9
50 7.7 12.2 15.4
100 7.4 11.8 14.9
1 7.7 12.2 15.4
Explanations:- 5 7.2 11.4 14.3
0 C 10 6.9 11.0 13.8
60
= Recommended application-Cold water installation 25 6.7 10.5 13.3
50 6.4 10.1 12.7
1 6.5 10.3 13.0
= Recommended application-Hot water installation 5 6.0 9.5 11.9
0 C 10 5.9 9.3 11.7
70 25 5.1 8.0 10.1
= Recommended application-Central heating installation 50 4.3 6.7 8.5
1 5.5 8.6 10.9
0 C 5 4.8 7.6 9.6
80 10 1.0 6.3 8.0
25 3.2 5.1 6.4
1 3.9 6.1 7.7
* Bracketed values apply where testing can be shown to have 0 C 5 2.5 4.0 5.0
o
been carried out for longer than 1 year at 110 C 95 (10)* (2.1)* (3.4)* (4.2)*

6
TECHINICAL MANUAL

LONG TERM PERFORMANCE

50
Hoop stress [MPa]

40

30

25

20
10 0C

20 0C
15
30 0C
40 0C
50 0C
10
9 60 0C
8 70 0C
7 80 0C
6 90 0C

5 95 0C

4 110 0C
3.5
3
2.5
Pipe 20 x 3.4mm,
2 10 bar internal pressure

Pipe 20 x 1.9mm,
1.5 4 bar internal pressure

1 5 10 25 50 100
Years

0.5
0,1 1 10 102 103 104 105 106
Time to failure[h]

7
 TECHINICAL MANUAL

3.0 PRODUCT DETAILS

3.1 REFERENCE STANDARDS

DIN 8077 Polypropylene (PP) pipes-Dimensions
DIN 8077 Polypropylene (PP) pipes- General quality requirements & testing
DIN 16962 Part 5 - Pipe joint assemblies & fittings for (PP) pressure pipes
General quality requirements & testing
Part 6 - Pipe joint assemblies & fittings for (PP) pressure pipes
Injection moulded Elbows for socket welding
Part 7 - Pipe joint assemblies & fittings for (PP) pressure pipes
Injection moulded Tee pieces for socket welding
Part 8 - Pipe joint assemblies & fittings for (PP) pressure pipes
Injection moulded Sockets & caps for socket welding
Part 9 - Pipe joint assemblies & fittings for (PP) pressure pipes
Injection moulded Fittings for butt welding
IS 9845 Method of analysis for determination of specific and/or overall migration of
constituents of plastic materials and articles intended to come into contact with
foodstuffs
IS 10500 Specification for Polypropylene & its copolymers for its safe use in contact with food
stuffs, Pharmaceuticals & drinking water

3.2 PRODUCT RANGE

3.2.1 PIPES As per DIN 8077 & DIN 8078

D d

8
TECHINICAL MANUAL

The Pipe is used for conveying HOT and COLD water/fluids/chemicals/compressed air in various plumb-
ing installations such as:
a. Single layer (Green Color) PPR Pipes for Indoor installations
b. Three layer (3) PPR Pipes for Indoor/Outdoor installations
Outer Layer (Green color) PPR is UV resistant, which makes pipes suitable
for use under direct sunlight Inner layer (White Color) PPR is antimicrobial which
provides hygiene and protection from internal bacterial growth
Middle layer (Black Color) PPR provides body strength to the pipe

The pipe can be custom manufactured in other colors for suitable quantity orders

PPR PIPE-PN10/SDR 11 (Per Meter)

PRODUCT DIMENSION PRODUCT DIMENSION

CODE mm Inch CODE mm Inch
GHI-20.10 20 1/2
´´ GHI-90.10 90 3´´
GHI-25.10 25 3/4
´´ GHI-110.10 110 4´´
GHI-32.10 32 1´´ GHI-124.10 124 47/8´´
GHI-40.10 40 11/4´´ GHI-160.10 160 6´´
GHI-50.10 50 11/2´´ GHI-180.10 180 7´´
GHI-63.10 63 2´´ GHI-200.10 200 77/8´´
GHI-75.10 75 21/2´´

PPR PIPE-PN16/SDR 7.4 (Per Meter)

PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm Inch CODE mm Inch
GHI-20.10 20 1/2
´´ GHI-90.10 90 3´´
GHI-25.10 25 3/4
´´ GHI-110.10 110 4´´
GHI-32.10 32 1´´ GHI-124.10 124 47/8´´
GHI-40.10 40 11/4´´ GHI-160.10 160 6´´
GHI-50.10 50 11/2´´ GHI-180.10 180 7´´
GHI-63.10 63 2´´ GHI-200.10 200 77/8´´
GHI-75.10 75 21/2´´

9
 TECHINICAL MANUAL

PPR PIPE-PN20/SDR 6 (Per Meter)

PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm Inch CODE mm Inch
GHI-20.10 20 1/2
´´ GHI-90.10 90 3´´
GHI-25.10 25 3/4
´´ GHI-110.10 110 4´´
GHI-32.10 32 1´´ GHI-124.10 124 47/8´´
GHI-40.10 40 11/4´´ GHI-160.10 160 6´´
GHI-50.10 50 11/2´´ GHI-180.10 180 7´´
GHI-63.10 63 2´´ GHI-200.10 200 77/8´´
GHI-75.10 75 21/2´´

3.2.2 FUSION WELD

COUPLER
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
CPL.16.20 16 mm CPL.75.20 75 mm
CPL.20.20 20 mm CPL.90.20 90 mm
CPL.25.20 25 mm CPL.110.20 110 mm
CPL.32.20 32 mm CPL.160.20 160 mm
CPL.40.20 40 mm CPL.200.20 200 mm
CPL.50.20 50 mm CPL.250.20 250 mm
CPL.63.20 63 mm CPL.315.20 315 mm

The COUPLER is used to join two pipes to each other by means of fusion welding. Its advantage allows
for the joining of short length pipes or replacing faulty pieces of pipe.
ELBOW 90o
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
ELB.90.16.20 16 mm ELB.90.75.20 75 mm
ELB.90.20.20 20 mm ELB.90.90.20 90 mm
ELB.90.25.20 25 mm ELB.90.110.20 110 mm
ELB.90.32.20 32 mm ELB.90.160.20 160 mm
ELB.90.40.20 40 mm ELB.90.200.20 200 mm
ELB.90.50.20 50 mm ELB.90.250.20 250 mm
ELB.90.63.20 63 mm ELB.90.135.20 315 mm
o
The ELBOW is used at corners where pipeline makes a turn of 90 .
ELBOW 45o*
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
ELB.45.16.20 16 mm ELB.45.90.20 75 mm
ELB.45.20.20 20 mm ELB.45.110.20 110 mm
ELB.45.25.20 25 mm ELB.90.160.20 160 mm
ELB.45.32.20 32 mm ELB.90.200.20 200 mm
ELB.45.40.20 40 mm ELB.90.250.20 250 mm
ELB.45.50.20 50 mm ELB.90.315.20 315 mm
ELB.45.63.20 63 mm
o o
The ELBOW 45 is used where the pipeline changes direction through 45 .

10
TECHINICAL MANUAL

EQUAL TEE
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
EQT.16.20 16 mm EQT.90.20 90 mm
EQT.20.20 20 mm EQT.110.20 110 mm
EQT.25.20 25 mm EQT.160.20 160 mm
EQT.32.20 32 mm EQT.200.20 200 mm
EQT.40.20 40 mm EQT.250.20 250 mm
EQT.50.20 50 mm EQT.315.20 315 mm
EQT.63.20 63 mm
o
EQUAL TEE is used to take an outlet/branch at 90 from main pipeline.
PLAIN UNION*
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
16 mm 90 mm
20 mm 110 mm
25 mm 160 mm
32 mm 200 mm
40 mm 250 mm
50 mm 315 mm
under development*
63 mm

PLAIN UNION is used to join two pipes coaxially. It provides facility of reopening the joint, basically for maintenance.
END CAP*
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
16 mm 90 mm
20 mm 110 mm
25 mm 160 mm
32 mm 200 mm
40 mm 250 mm
under development* 50 mm 315 mm
63 mm
END CAP is used as a stopper at the end of pipeline. It also seals the top end of pipeline for pressure
leakage test after completion of piping work.
EQUAL CROSS TEE*
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
16 mm 75 mm
20 mm 90 mm
25 mm 110 mm
32 mm 160 mm
40 mm 200 mm
50 mm 250 mm
63 mm 315 mm
under development*
o
EQUAL CROSS TEE is used to take two branches/outlets at 90 from pipe line at the same junction but in
opposite directions.

11
 TECHINICAL MANUAL

PIPE CLAMP* REDUCER

PRODUCT DIMENSION
CODE mm
PBR.45.16.20 16 x 20
PBR.45.20.20 25 x 20
PIPE CLAMP is PBR.45.25.20 32 x 20
used to secure PBR.45.32.20 32 x 25
the pipeline in it’s PBR.45.40.20 40 x 32
installed position PBR.45.50.20 50 x 32
on the wall.
PBR.45.63.20 63 x 40
under development* REDUCER is used to joint bigger diameter pipe to smaller
diameter pipe coaxially.
o
REDUCING ELBOW 90
PRODUCT DIMENSION
CODE mm
PBR.90.16.20 16 x 20
PBR.90.20.20 25 x 20
PBR.90.25.20 32 x 20
PBR.90.32.20 32 x 25
PBR.90.40.20 40 x 32
PBR.90.50.20 50 x 32
REDUCING ELBOW is used to joint two
PBR.90.63.20 63 x 40 o
different sizes of pipes at 90 corner/turn.
REDUCING TEE
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
16 x 20 63 x 25
25 x 20 63 x 20
32 x 20 75 x 63
32 x 25 75 x 50
40 x 32 75 x 40
50 x 32 75 x 32
63 x 40 90 x 75
63 x 32 110 x 90
o
REDUCING TEE is used to take a smaller size branch pipe at 90 from main pipe.
3.2.3 TRANSITION FITTINGS WITH METALLIC THREADED INSERTS
MALE THREADED TEE
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
MTT.16.050.20 16 x 1/2
MTT.32.050.20 32 x 1/2

MTT.16.075.20 16 x 3/4 MTT.32.075.20 32 x 3/4

MTT.20.050.20 20 x 1/2 MTT.40.125.20 40 x 11/4
MTT.20.075.20 20 x 3/4 MTT.50.125.20 50 x 11/4
MTT.25.050.20 25 x 1/2 MTT.63.125.20 63 x 11/4
MTT.25.075.20 25 x 3/4

MALE THREADED TEE is used to join a female threaded metallic fitting with PP-R line for taking Outlet.

12
TECHINICAL MANUAL

FEMALE THREADED TEE

PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
FTT.16.050.20 16 x 1/2 FTT.32.050.20 32 x 1/2
FTT.16.075.20 16 x 3/4 FTT.32.075.20 32 x 3/4
FTT.20.050.20 20 x 1/2 FTT.40.125.20 40 x 11/4
FTT.20.075.20 20 x 3/4 FTT.50.125.20 50 x 11/4
FTT.25.050.20 25 x 1/2 FTT.63.125.20 63 x 11/4
FTT.25.075.20 25 x 3/4
FEMALE THREADED TEE is used to join a male threaded metallic fitting with PP-R line for taking Outlet.

MALE THREADED ELBOW PRODUCT DIMENSION

CODE mm

MTE.90.16.050.20 16 x 1/2 MTE.90.32.050.20 32 x 1/2

MTE.90.16.075.20 16 x 3/4 MTE.90.32.075.20 32 x 3/4
MTE.90.20.050.20 20 x 1/2 MTE.90.40.125.20 40 x 11/4
MTE.90.20.075.20 20 x 3/4 MTE.90.50.125.20 50 x 11/4
MTE.90.25.050.20 25 x 1/2 MTE.90.63.125.20 63 x 11/4
MTE.90.25.075.20 25 x 3/4
MALE THREADED ELBOW is used to join a female threaded metallic fitting with
o
PP-R line at 90 corner/turn

COUPLER-MALE THREADED PRODUCT DIMENSION

CODE mm
MTE.90.16.050.20 16 x 1/2
MTE.90.16.075.20 16 x 3/4
MTE.90.20.050.20 20 x 1/2
MTE.90.20.075.20 20 x 3/4
MTE.90.25.050.20 25 x 1/2
MTE.90.25.075.20 25 x 3/4
MTE.90.32.050.20 32 x 1/2
MTE.90.32.075.20 32 x 3/4
MTE.90.40.125.20 40 x 11/4
COUPLER-MALE THREADED is used to join a MTE.90.50.125.20 50 x 11/4
female threaded metallic fitting with PPR line. MTE.90.63.125.20 63 x 11/4

COUPLER-FEMALE THREADED PRODUCT DIMENSION

CODE mm

FTS.16.050.20 16 x 1/2 FTS.25.075.20 25 x 3/4

FTS.16.075.20 16 x 3/4 FTS.32.050.20 32 x 1/2
FTS.20.050.20 20 x 1/2 FTS.32.075.20 32 x 3/4
FTS.20.075.20 20 x 3/4 FTS.40.125.20 40 x 11/4
FTS.25.050.20 25 x 1/2 FTS.50.125.20 50 x 11/4
FTS.50.125.20 63 x 11/4

COUPLER-FEMALE THREADED is used to join a male threaded metallic fitting

with PP-R line.

13
 TECHINICAL MANUAL

3.2.4 VALVES*
GATE VALVE*
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
16 mm 40 mm
20 mm 50 mm
25 mm 63 mm
32 mm

GATE VALVE is used to start, regulate and stop the water flow in pipeline.
under development*
DESIGNER VALVE*
PRODUCT DIMENSION PRODUCT DIMENSION
CODE mm CODE mm
16 mm 40 mm
20 mm 50 mm
25 mm 63 mm
32 mm

DESIGNER VALVE is used in concealed piping to start, regulate and stop the
water flow in pipeline. It is designed to have an aesthetic look.
under development*
DOUBLE UNION BALL VALVE* PRODUCT DIMENSION
CODE mm
16 mm
20 mm
25 mm
32 mm
40 mm
50 mm
63 mm

DUB VALVE is used to start, regulate and stop the water

flow in pipeline
3.2.5 WELDING ACCESSORIES
CUTTER

14
TECHINICAL MANUAL

POLYFUSION DEVICES (WELDING DEVICES)

PRODUCT DIMENSION
CODE mm
20 - 40
40 - 63
75 - 100
160

3.3 QUALITY TESTS

NOTE: PRODUCTS WITH * ARE UNDER DEVELOPMENTAL STAGE

Strict quality control of incoming raw materials and factory operations

ensures the continuous production of high quality products. All pipes & Fittings are manufactured to meet or
exceed the test values, frequency of testing and functional requirements of the DIN standards. All
raw materials are tested and certified prior to manufacturing range of products. Release for shipment is made
only after all prescribed tests are completed and the results have met GHI and the customers’ requirements.

In order to assure a high and consistent quality, we have established in-house laboratory with modern testing
equipments and have highly skilled and trained technicians.
The quality assurance plan covers:-
a. ACCEPTANCE TESTS
i. Incoming Inspection & Testing of
• Raw Material for MFI
• Product accessories for Surface Finish, Fitment & Operation
• Rubber parts for Hardness & Dimensions
ii. In-process Inspection & Testing of
Pipes, Fittings & Valves for Visual appearance, Fitment with Gauges & Dimensions
iii. • Final Inspection & Testing of
• Pipes for Visual appearance, Dimensions, Hydraulic Test, Heat Reversion Test &
Hammer Test
• Fittings for Visual appearance, Dimensions, Hydraulic Test & Hammer Test
• Valves for Drip Proofness Test & Hydraulic Test
b. Type Tests
i. Pipes & Fittings for Long Term Hydraulic Test
ii. Valves for Thermal Shock Test
iii. Piping installation including assemblies of Pipes, Fittings & Valves for
• Hot & Cold Water Cycle Test
• Water Hammer Test
iv. Threaded Brass Inserts for Torque Test & Material Composition

15
 TECHINICAL MANUAL

4.0 PRODUCT DETAILS

4.1 THERMAL EXPANSION
A pipe line which is subjected to a variation of temperatures changes its length if it is free to do so. This
change in length is proportional to the unit linear coefficient of thermal expansion. Any linear expansion or
contraction caused by a thermal gradient can easily be calculated using the following formula.

Where:
Expansion(+) or contractor(-) in length, (mm)
Intial pipe length, (Meter)
Coefficient of thermal expansion( for PP-R 0.15mm/moc)
Temperature, difference ( C)
o

Example: for 5 meter PP-R line operating between 25 to 55 C

o

(55-25)=30 C
o

Then, 0.15 X 5 X 30 = 22.5mm

The expansion and contraction adjustment of PPR pipeline is generally made in longitudinal direction only.
Enough space shall be provided and proper type of supports shall be used to allow the free movement of
pipe in axial directions.

Once the change in length of pipeline on account of thermal expansion/contraction has been calculated, a
correct planning of pipelines is necessary to ensure that its effect do not cause deformation of the piping
itself. PPR systems make it possible to install easy and convenient compensation for change in length using
the suitable provision of following:

• Fix supports & Sliding supports

• Free flexible pipe segment; (Expansion Arm).
• Free flexible pipe loop (Compensation Loop).

Fixed and Sliding supports secure external pipelines to the masonry structure of the building to prevent the
movements generated by thermal expansion, totally or partially.

Fixed Supports:-are used when the axial expansion of the pipe line should be limited. Fixed support
provides a rigid connection between external pipeline installations with masonry structure. The fixed
supports must normally be positioned where the system changes direction (Elbows, Tees, etc.) & near to
Valves, Cocks, Water meter, etc. to ensure that expansion forces are not discharged in these points. In all
cases, fixed support should always be provided next to any joint in the pipeline created using any welded
fitting.

Obviously the fixed supports limit the length of section of pipe free to expand, and reduce the relative
change in length value.
Sliding Supports:-are used to allow the pipe to move axially in both directions. They have to be positioned
well away from joints made using welded fittings, on a free length of the pipes surface. The sliding support
collar must be absolutely free from pipe diameter otherwise it may damage the surface of the pipe where

16
TECHINICAL MANUAL

it is installed.

Sliding support also ensures that the pipeline remain straight in spite of thermal stresses.

WALL
WALL

PIPE PIPE
PIPE PIPE

FITTING
FIXED FITTING FIXED
SUPPORT
FIXED SUPPORT
FIXED
SUPPORT SUPPORT

WALL
WALL

PERMITTED AXIAL TRAVEL

PERMITTED AXIAL TRAVEL

PIPE PIPE
PIPE PIPE

SLIDING
SUPPORT
SLIDING
SUPPORT

PIPE Horizontal clamp spacing distance PIPE Vertical clamp spacing distance
DIA. according to temperatures, cm DIA. according to temperatures, cm
mm 20 C 30oC 40oC 50oC 60oC 70oC 80oC
o
mm 20 C 30oC 40oC 50oC 60oC 70oC 80oC
o

20 65 63 61 60 58 53 48 20 85 82 78 78 75 69 62
25 75 74 70 68 66 61 56 25 98 96 91 88 86 79 73
32 90 88 86 83 80 75 70 32 117 114 112 108 104 98 91
40 110 110 105 100 95 90 85 40 143 143 137 130 124 117 111
50 125 120 115 110 105 100 90 50 163 156 150 143 137 130 117
63 140 135 130 125 120 115 105 63 182 176 169 163 156 150 137
75 155 150 145 135 130 125 115 75 202 195 189 176 169 163 150
90 165 160 155 145 140 130 120 90 215 208 202 189 182 169 156
110 175 175 170 165 155 145 135 110 228 228 215 215 202 189 176

Free flexible pipe segment (Expansion Arm): - with the help of free flexible pipe segment, provided at
the position of change in direction, the change in length of pipeline is totally compensated. The length of
free flexible pipe segment is calculated using following formula:

17
 TECHINICAL MANUAL

Length of free flexible

segment = LS=C d
SOCKET PIPE
SOCKET PIPE

Where
LS = Length of free flexible
segment (mm)
FIXED SLIDING
FIXED
SUPPORT SLIDING
SUPPORT
SUPPORT SUPPORT

C = Constant of material

LS
LS
(for PP-R, C=30).
d = pipe outside diameter (mm).
FIXED
FIXED = Expansion or contraction
SUPPORT
length (mm).
SUPPORT

Free flexible pipe loop (Compensation Loop): - If the change in length cannot be compensated using
expansion arm, it is necessary to install a free flexible loop (Compensation loop). Free flexible bend can be
o
easily prepared on site with required lengths of PPR pipe & 4 nos. of 90 elbows.

FIXED SLIDING FIXED SLIDING

FIXED SLIDING FIXED SLIDING
SUPPORT SUPPORT SUPPORT SUPPORT
SUPPORT SUPPORT SUPPORT SUPPORT

SOCKET SOCKET
SOCKET SOCKET
B
B B
10dB
10d
LS
LS

SLIDING
SUPPORT
SLIDING
SUPPORT
FLEXIBLE COMPENSATOR MADE OF PP-R PIPE AND 90%D ELBOW
FLEXIBLE COMPENSATOR MADE OF PP-R PIPE AND 90%D ELBOW

To prepare a free flexible loop you have to calculate:

• The length of free flexible segment (LS) with the help of formula as explained in Free flexible pipe
segment (Expansion Arm)

• The minimum width (B) between two arms of the loop = 10 times the outside diameter of the
pipe.

Examples of fixed and sliding supports in pipe section: -

T
T

T
T

L
T
T

Fix Fix
Fix
Support
Fix
Support L L L
T T
Fix Fix
L T T
T

Support Support Support Support L T T T T

T T T T T T T T T T
T

T
T

L
T T T T T T T
T T T T T T T L L L T T
L5

L1 L2 L3 L4
L T T
T

L T T T T
L5

L1 L2 L3 L4
L5

L1 L2 L3 L4 T T T
T

L4

L3

T
T

L
L
L4

L3

L4

L3

Length absorption with compensation loop L L T T

L L T T
Length absorption in a compensation
with
Length absorption straight sectionloop
of pipeloop
with compensation T T T
T T T T
L1

T
in a straight section section
in a straight of pipe of pipe L
L
L1

21

L
LL

T T
L L T L
T
L2

T T T
L2

T T
T

T
T

Fixed

L Fixed Fixed
support

L L T T support T
support T

FixedT support
T T in the
T middle Fixed
T support
T T atTbase
Fixedofin
Fixed support the
thevertical
supportmiddle pipe
in the section
middle Fixed support of at
Fixed vertical
base pipe
support section
at base
of the vertical
of the pipe section
vertical pipe section of vertical
of pipe section
vertical pipe section

18
TECHINICAL MANUAL

4.2 LAYING IN SANITARY SHAFT / PIPE DUCT OF A BUILDING

RECOMMENDATION
No. DESCRIPTION
FOR PIPE CONNECTION

LS
LS
PIPE CONNECTION CAN BE MADE
1 AT SOME DISTANCE AWAY FROM
LS
THE WALL
When making the apartment
THE CONNECTION PIPE CAN pipe connections from main pipe
LS

BE PASSED THROUGH A HOLE going through the sanitary shaft

2 MUCH LARGER THAN THE of the building, the alternative
PIPE DIAMETER techniques above can be
applied in order to compensate
LS
LS
for thermal expansion &
THE CONNECTION CAN BE
3
LS

MADE THROUGH A BRANCH contraction

PIPE TO PROVIDE FLEXIBILITY LS

4.3 BENDING PIPE MINIMUM BENDING

DRAWING DIAMETER RADIUS
During laying of pipeline, PPR pipes may be required (mm) (mm)

20 160
to be bent. Bending shall be done by using hot air
blowing at 140 C. Direct heating by open flame must/
o P 25 200

should be avoided. Radius for PPR pipe bend should R

32 256

be minimum 8 times its diameter. The table indicates 40 320

minimum bending radius for each size of pipe.
50 400

4.4 INSULATION
4.4.1 FOR HOT WATER
When conveying hot water through any Thermal conductivity of Insulation material
pipe, heat is transferred through the pipe Pipe
0.030W/mk 0.035W/mk
Size mm
wall PPR pipes posses Recommended minmium insulation thickness in mm
a much lower coefficient of thermal 20 6 10
conductivity (0.24W / mK) compared to 25 6 10
metal pipes. Therefore, most often it may 32 10 13
not be required to insulate the pipelines 40 10 13
which are used for hot water concealed 50 10 13
application. However, for centralized 63 13 20
heating systems, to prevent heat loss and 75 20 20
to isolate the pipelines from other utilities, 90 20 25
it is advisable to insulate these lines. The 100 25 32
required thickness of insulation is quite
small as compared with conventional lines. The above table indicates the recommended insulation
thickness for different pipe sizes.

19
 TECHINICAL MANUAL

4.1.2 FOR COLD WATER

Potable cold water plants have to be protected against heat gain and the formation of condensation. Standard
value for the minimum thickness as stipulated in DIN-1988, part 2 have to be taken from the following
table
o
Minimum insulation thicknessfor the insulation of potable water pipes (10 C) as per DIN 1988, part 2
Type of installation Insulation thickness (for 0.04 W/mk thermal
conductivity material) in mm
Open installed pipes, in no heated room (i.e. celler) 4 mm
Open installed pipes, in no heated room 9 mm
Pipe in a duct, without warm pipe 4 mm
Pipe in a duct, beside warm pipe 13 mm
Pipe in a pipe chase riser 4 mm
Pipe in a pipe chase, beside warm water pipes 13 mm
Pipe in a concrete floor 4 mm

(Note :- Recommended insulation for all sizes of pipes for different water temperature at various level of
humidity are available on request)

4.5 RESISTANCE TO ULTRA VIOLET (UV) RAYS :-

PPR pipes & fittings have sufficient U.V. stability to provide protection from UV rays. The
Pipes are three layers, which enables targeted UV protection.

4.6 SUITABILITY FOR DRINKING WATER:

PPR pipes & fittings meet the requirements of IS 10500-91 for drinking water and IS 10146-
87 for Reachable additives as it is safe for drinking water. The product is Food Grade.

4.7 FIRE RESISTANCE:

PPR pipes & fittings have combustion point 330 oC & burning point 360 oC. These conform
with B2 class fire requirements of normal combustibility according to DIN 4102. On fire, PPR pipes &
fittings emit carbon dioxide and water. Other than this, carbon monoxide gas, molecular hydrocarbon and
oxidation products of these are also emitted in proportion to the availability of oxygen. Even if the fire is
incomplete, the materials emitted are less poisonous than wood or similar materials on fire under the same
conditions.

The smoke that comes out from PPR fire is non-hazardous at room temperature but fumes formed at elevated
temperatures can cause irritation.

4.8 LOW TEMPERATURE RESISTANCE :

At lower temperature of 0 C and below, the flexibility of PPR pipes reduces and its impact strength also
reduces. This makes pipes more prone to mechanical damages against impact loads. To avoid the damages
at low temperature, it is advisable to insulate the pipe lines.(Refer ‘Insulation’ given under 4.2.2)

20
TECHINICAL MANUAL

5.1 GENERAL GUIDELINES

While designing the PPR piping system, one should be aware that PPR piping is quite different from other
traditional materials like GI or Copper as well as PVC or CPVC. For good and safe design and installation,
the following shall be taken into account.
• Pipes & fittings have different dimensions from other types of pipes and fittings. Even though
the bore diameter of pipe is less than the equivalent metal or plastic pipe, the flow is more due to
smoothness & less friction (Refer table: “Pipe Friction Loss & Flow Rate”) Hydraulic calculation
should be done each time for the best choice of pipeline diameters.
• Linear thermal expansion/contraction of PPR pipes is more as compared with metal pipes. This
needs to be taken into consideration designing and installation to avoid stressing of pipeline by
providing flexible free length and proper support. (Refer section 4.1 Thermal expansion).
• Refer section 2.3 for STANDARD WORKING CONDITION AND SERVICE LIFE for
designing.
• Use 3 layer pipes for outdoor installations.
• Use black pipes for solar heating system.
• Provide insulation for centralized heating systems and chilled water systems (Refer section 4.4
Insulation)
• Refer section 8 for Dos & Don’ts

5.2 PIPELINE DESIGN

5.2.1 FLOW RATE
Analytical flow is typical for each analytical section. Draw-off point’s water quantity shall be worked out,
taking into consideration water consumption (which is not simultaneous at all draw-offs). The following
table gives formula for calculating the analytical flow for different types of application:-

Application
Residential buildings
Commercial buildings
Hotels & shopping Malls
Hospitals
Schools
Design flow rate Q12 in lps as per DIN 1988 part 3 can be
calculated from following formula
Formula for 0.7 < Eq< 20lps Formula for Eq > 20lps
Q=0.682 (Eq)0.45 - 0.14 Q=1.7 (Eq)0.25 - 0.7
Q=0.682 (Eq)0.45 - 0.14 Q=0.4 (Eq)0.54 - 0.48
Q=0.4 (Eq)0.086 Q=1.08 (Eq)0.5 - 1.82
Q=0.698 (Eq)0.5 - 0.12 Q=1.08 (Eq)0.5 - 0.12
Q=0.698 (Eq)0.5 - 0.12 Q=0.25 (Eq)0.65 - 1.25
Q=4.4 (Eq)0.27 - 3.41 Q= -22.5.08 (Eq)0.5 - 11.5

Where, Q = Standard outflow from the draw-off points, lps

Eq = Sum of all standard outflows from the draw-off points serviced by
dimensional section of the installation, lps

Qp = Design flow, lps

• Maximum design flow velocity in service pipe should be 2 M/s.

• In supply mains, the maximum flow velocity shall be between
2.5 to 5.0 M/s.

• Select the size of main pipe considering the flow Eq

21
 TECHINICAL MANUAL

DESIGN FLOW RATES OF COMMON WATER POINTS

Minimum Type of water Calculated flow on taking:

Pressure Mixed water Only cold or warm
Cold/warm water potable
0.5 Taps Without air inlet DN 15 - 0.30
0.5 Taps Without air inlet DN 20 - 0.50
0.5 Taps Without air inlet DN 25 - 1.00
1.0 Taps With air inlet DN 10 - 0.15
1.0 Taps With air inlet DN 15 - 0.15
Shower heads for purfication
1.0 0.10 0.20
showers DN 15
1.2 Flush Valves DN 15 (Toilet) - 0.70
0.4 F.V. DN 25 (Toilet) - 1.00
1.0 Flush Valves DN 15 (Urinal) - 0.30
1.0 Domestic dish washers DN 15 - 0.15
1.0 Domestic washing machine DN 15 - 0.25
Mixing batteries for:
1.0 Bath Shower DN 15 0.15 -
1.0 Bath-tubs DN 15 0.15 -
1.0 Kitchen sinks DN 15 0.07 -
1.0 Washstands DN 15 0.07 -
1.0 Bidet DN 15 0.07 -
1.0 Mixing battery DN 20 0.30 -
0.5 Gayser DN 30 - 0.15
1.0 Gayser DN 20 - 0.20

5.2.2 PRESSURE LOSS

In normal piping, two types of pressure loss can be found,
1 Distributed pressure loss related to pipe roughness, dimensions, physical properties and
velocity of the liquids.
2 Local loss related to elbows, tees, valves and fittings which cause a remarkable variation in
the liquid flow.

5.2.2.1 DISTRIBUTED PRESSURE LOSS

The PPR pipe has extremely smooth inner surface compared to metal pipes. Therefore, pressure loss is
quite low.
Pressure loss changes are very little in the normal span of operating temperatures (up to 60 C) in potable
o

water pipeline.
The details are available on request.

22
TECHINICAL MANUAL

5.2.2.2 LOCAL PRESSURE LOSS

Local resistance coefficient “r”
The PPR pipe has extremely smooth inner surface
PP-R plumbing fittings.
compared to metal pipes. Therefore, pressure loss
is quite low. Symbol for Coefficient
Name of pp-r fitting
pp-r fitting value (r)
Pressure loss changes are very little in the normal Coupler 0.25
span of operating temperatures (up to 60 C) in
o

Reducer Single stage reducer 0.50

potable water pipeline. Double stage reducer 0.60
Three stage reducer 0.70
The details are available on request. Four stage reducer 0.85

Elbow 90o 1.2

In pipeline, local pressure loss takes place due to Elbow 45o 0.5

presence of fittings which can be calculated using Tee 1.8

following formula
Male / Female Threaded Tee 1.8
( r ) V26
R=
2g Reducing Tee 3.0
Where,
Male/Female Treaded Adaptor 0.5
R = Total local pressure loss in (mm) Reducing Male/Female Adaptor 0.8
r = Local resistance coefficient value Male/Female Treaded Elbow 1.4
as given in following table Reducing Treaded Elbow 1.6
V = Mean velocity in fluid in (m/s) Valve 20 9.5
g = Acceleration of gravity = 9.81 (m/s2) 25 8.5
32 7.6
6 = Specific gravity of water = 1000 (kg/
m3) Union 8.3

Note :-
1) These are reference values and they vary according to water temperature.
2) As fitting diameter increases, the value of ‘r’ decreases.

23
 TECHINICAL MANUAL

5.3 HOLE REPAIRING

In case of accidental hole formation in pipe line due to drilling or piercing of pointed object, the pipe line
can be repaired as follows:

1 2

Simultaneously heat the hole section in the pipe line and repair
bar using repair section die and welding device for about 5 to 7
Accidental hole formation in pipe line. seconds depending upon the pipe thickness.

3 4

Insert heated repair bar in the hole After cooling, cut the repair bar
up till the full depth and hold it for a projected outside the pipe line using
minute. pipe cutter.

6.0 TESTING THE INSTALLATION

6.1 PRESSURE TEST
According to DIN 1988, PPR Pipeline for portable water installations have to be (before concealing)
hydraulically pressure tested as follows -

While carrying out the pressure test the material properties of PPR lead to expansion of pipe. This influences
the test result. A further influence of the result can be caused by the thermal expansion of PPR pipes.
o
Different temperatures of pipe & test medium lead to alteration of pressure. A temperature change of 10 C
corresponds to pressure difference of 0.5 to 1 bar therefore, the highest possible constant temperature of the
test medium has to be ascertained at the hydraulic pressure test of installations with PPR pipes.
6.1.1 PRIMARY TEST
For primary test, a pressure of 1.5 times of rated pressure shall be applied for a duration of 30 minutes.
During this test, pressure drop shall be < 0.6 bar.
6.1.2 MAIN TEST
After completion of primary test, main test must be conducted, which has to be effected with a test pres-
sure of alternate 1 bar and 10 bar for every 5 minutes interval for 2 hours.

24
TECHINICAL MANUAL

CHEMICAL CONC. PP-R

TEMPERATURE
% 20 60
Acetone 100 R C
Acetic Acid 100 R C
Acetic Anhydride 100 R C
Alum sat. R R
Ammonia Aq. conc. R R
Ammonium Acetate Aq. any R R
Ammonium Phosphate any R R
Amyl Alcohol pure R R
Aniline 100 R C
Beer R R
Benzaldehyde 100 R C
Benzene 100 N R
Borax Aq. R R
Boric Acid Aq. sat. R R
Butanol 100 R R
Butyl Acetate 100 R N
Calcium Chloride Aq. sat. R R
Calcium Nitrate sat. R R
Citric Acid Aq. sat. R R
Coconut oil R C R = Recommended,
Cyclohexanol 100 R R Durable
Cyclohexanone 100 R N
Formaldehyde 40 R R
Formic Acid 50 R R C = Caution Practically
Glycerine 100 R R durable under
Heptane 100 R N
suitable conditions
Hydrochloric Acid conc. R R
Hydrogen Peroxide 10 R R
Isopropyl Alcohol 100 R R N = Not Recommended
Lactic Acid 85 R R
Linseed oil R R
Magnesium Salts Aq. sat. R R
Methyl Alcohol 100 R R
Olive Oil R R
Oxalic Acid Aq. sat. R R
Palm oil R N
Peanut oil R C
Phospheric Acid 50 R R
Potassium Chlorate Aq. sat. R R
Pottacium Dichromate Aq. sat. R R
Potassium Sulphate Aq. sat. R R
Pyridine 100 R C
Salted Water any R R
Sea Water R R
Soap R R
Sodium Bicarbonate Aq. sat. R R
Sodium Chloride Aq. sat. R R
Sodium Perborate Aq. sat. R R
Sodium phosphates Aq. sat. R R
Sodium Sulphate Aq. sat. R R
Starch, Starch solutuion Aq. any R R
Sugar (dry) R R
Sulphuric Acid 96 R C
Tartaric Acids Aq. sat. R R
Toluene 100 C N
Urea Aq. sat. R R
Vinegar comm. R R * For more details please
Water 100 R R ask us

25
 TECHINICAL MANUAL

8.0 DOS & DON’TS FOR PP-R PIPE PLUMBING SYSTEM

No. ACTIVITY RECOMMENDATION

Storage
Although PPR Pipe system material is stabilized for
1 use at elevated temperature do not expose the pipes &
fittings to direct sunlight.

Storage

PPR Pipe storage height should not be more

2 1.5M
than 1.5 meter.
1.5M
1.5M
1.5M

Transporation
When transporting, PPR pipes should be loaded in
3 proper manner, otherwise pipes may get deformed.

The PPR system should be protected from impact

4 of hard and sharp objects.
Handling

Avoid cutting tools which create burns. Cutting should

5 be square to pipe axis (use only provided cutters).
Cutting
Preparation for welding
Before welding / joining clean the surface of PPR
6 Pipes & Fittings with clean piece of cloth and
then start welding.

While welding of PPR Pipes and fittings check

that thermostat of welding machine and dies have
7 reached correct temperature (260oC). While welding,
the pipe must not be twisted.
Heating

Avoid air draughts during welding to avoid stress

8 in the welds.
Welding

Welding machines shall be earthed properly during

9 use.
Safe welding

26
TECHINICAL MANUAL

No. ACTIVITY RECOMMENDATION

10 Do not cool welding machine in water.

Safe welding

11 Do not over-tight threaded fittings & valves.

Thread joint

Use only Telfon tape or Telfon thread sealant for

12 threaded joints and avoid over wrapping with excess
Thread tape.
joint sealing
Bending

13 Do not apply heat directly.

Bending
While bending the pipe, the bending radius should be
14 more than 8 times the diameter of pipe.
R=8D(Min)

Installation at
low temperature
15 PP-R pipes & fittings kept at temperature

o
At sub zero temperatures (0 C & below) PPR Pipe
system tends to break under impact.
16 Therefore, installation at low temperatures should
be made with care, and the pipe lines should be
insulated.
Solar systems

17 The black PPR pipe line.

Outdoor installation

18 Use 3 Layer Pipe for outdoor application.

27
 TECHINICAL MANUAL

9.0 JOINTING METHOD OF PPR PIPES

& FITTINGS

CUTTING
• Cut pipe at right angle to its axis using burr-free cutter.
• Ensure that pipe is free from burrs or cutting chips.
• Clean the pipe & fitting perfectly before welding.
• Mark welding depth at the end of pipe.

HEATING
• Mount the suitable dies on heating element of welding machine
according to the diameter of pipe and fitting to be welded.
• Connect the welding machine to 220 volts A.C. power supply.
• Select 2600C temperature on the welding machine thermostat.
• Wait until the welding machine reaches the required working
temperature.
• Insert the pipe and the fitting in the dies by exerting light pressure.
• For heating time, refer to the table given for different sizes of pipes.

WELDING
• After heating, quickly insert pipe into the fitting by exerting light
pressure.
• Any misalignment should be corrected immediately after insertion
to avoid any stress in the weld.
• Allow the joints to cool as per cooling time given in table.

RECOMMENDED TIME FOR PP-R

FUSION JOINTS

PIPE WELDING HEATING WELDING COOLING-

DIA. DEPTH TIME TIME TIME
(mm) (mm) (Sec.) (Sec.) (Min.)
20 14.50 6 4 2
25 16.00 7 4 2
32 18.00 8 6 4
40 20.50 12 6 4
50 23.50 18 6 4
63 27.50 24 8 6
75 30.00 30 8 6
90 33.00 40 8 6
110 37.00 50 10 8
160 55.00 60 15 10

28