AB-3P Technical Reference Manual

THE NEXT MILLENIUM WATER PIPE SYSTEM
TECHNICAL
REFERENCE DATA
REV. 0A
FOR
HIGH IMPACT RESISTANT, ANTI-BACTERIA 3 LAYER PIPE
®
&
EPOXY POWDER FUSION BONDED
MECHANICAL JOINT DUCTILE IRON FITTING SOLUTION
®
AND OTHER ACCESSORIES
WWW.MEPLAS.COM.MY E-MAIL: MEPLAS@STREAMYX.COM
TECHNICAL REFERENCE DATA Z:₩08 Brochure₩ZZ Old Data₩Technical Data₩Excel n Word file₩2007-04-21 AB-3P
Technical Reference Manual.doc
TABLE OF CONTENTS
1 INTRODUCTION 5
1.1 What is AB-3P? 5
1.2 How to make AB-3P? 5
1.3 No uPVC-phobia! Why? No backyard product. 5
1.4 Long time proven performance. 5
1.5 Certificate and Registration 5
1.6 System Solution 6
1.7 Superior Design 6
1.8 Color and marking 6
1.9 Real Lifetime, pipe for our descendant. 6
1.10 Super Fast Construction 6
1.11 Residual Chlorine and Bio-Film 6
2 AB-3P PROPERTIES 6
2.1 Ambient temperature and Pipe pressure rating 7
2.2 Chemical resistance 8
2.3 Behavior in Fire 8
2.4 Abrasion Resistance 8
3 AB-3P/AB-DF PRODUCT FEATURES AND BENEFITS AB-3P PIPE 9

3.1.1 General 9
3.1.2 Certification and Test Criteria 9
3.1.3 Unique Spigot Rubber Ring Joint (Bell-Mouth Joint) 10
3.1.4 Anti-Bacteria, Safety Proven Nano-Technology 10
3.1.5 Pressure Pipes with Very Low flow friction 10
3.1.6 Residual Chlorine Absorption 10
3.1.7 Bio-Film 11
3.2 AB-DF Epoxy Coated Ductile Iron Fittings for Heavy Duty Application 11
3.2.1 General 11
3.2.2 Certification complied to BS/EN 545 12
3.2.3 AB-DF GLAND DESIGN – ADVANTAGES 12
3.2.4 AB-DF GLAND DESIGN – Exposed Application 13
4 PIPELINE DESIGN 14
4.1 Hydraulic design 14

4.1.1 Flow Calculation 16
4.1.2 Head Loss Calculation 16
4.1.3 Pipe INTERNAL Diameter Selection 16
4.1.4 Pressure class selection 17
4.1.5 Water hammer surges and cyclical effects 17
4.2 Structural Design 19

4.2.1 Minimum Cover Height 20
4.2.2 Thrust block for fittings 20
4.3 Above ground Installation 20

4.3.1 Protection against ultra violet (UV) 21
4.3.2 Heat Expansion & Contraction 21
4.3.3 Pipe movement 22
4.3.4 Exposed Pipe support 23
5 INSTALLATION 24
5.1 Transportation, Handling and Unloading 24
5.2 Storage 24
5.3 Fabrication, Cutting 25
5.4 Installation: Underground Trench Construction 26
5.5 Installation: Above Ground Exposed Construction 28

5.5.1 Protection against ultra violet (UV) 28
5.5.2 Heat Expansion & Contraction & Pipe movement 28
5.6 Jointing using “Supa-Tite” Rubber Ring Joints (Above and under ground) 28
5.6.1 Jointing Procedure (Factory Rubber ring inserted Pipe) 28
5.6.2 Jointing Procedure (Site Rubber ring insertion) 29
5.6.3 Various Method of Assembly for AB-3P Bell-Mouth Pipe 29
5.7.1 Assembly Procedure 32
5.7.2 Thrust block design for AB-DF Ductile Iron Fitting (Anchor Block) 34
5.16 Pre-Assembly and laying 41
5.17 Site Testing 41
6 REPAIRING 42
7 TRAINING PROGRAM 42
8 PRE-SALES SERVICE (PSS) & AFTER SALES SERVICE (ASS) 43
APPENDIX 1. GENERAL PROPERTIES OF AB-3P 44
APPENDIX 2. AB-3P INTERNAL DIAMETER, OUT-DIAMETER, THICKNESS QUICK REFERENCE

TABLE 45
APPENDIX 3. AB-3P CHEMICAL RESISTANCE CHART 46
APPENDIX 4. SAMPLE THRUST BLOCK DIMENSION GUIDELINE 60
APPENDIX 5. RECOMMENDED JOINTING METHOD TABLE 66
AB-3P & AB-DF Pressure Piping System
Technical Reference Data
1 Introduction
1.1 What is AB-3P?
AB-3P stands for Anti-Bacteria 3 Layer pipe. This patented unique High impact resistance High
Tensile strength polymer pipes are manufactured from a kind of PVC (polyvinyl chloride
polymer) but with differently modified formula and characteristics for inner and outer skin layer
and center layer. This unique pipe is 2nd generation of famous Korean High impact resistant
water pipe called HI-3P. HI-3P shows its excellent performance in Korea for last 15 years and
well accepted to Korean government authority. It basically meets and surpass all KS M 3401
(HI-VP) standard and JIS K 6742 and shows better performance than Japanese HI-VI.
1.2 How to make AB-3P?
AB-3P and HI-3P is produced using the same co-extrusion process. Normal PVC-U pipes are
produced with single extruder but AB-3P extrusion needs two extruders per each line. Normal
PVC-U pipe were introduced in Malaysia in the 1970's and are once widely accepted material
for use in water supply, irrigation and sewerage but tainted its reputation with bad quality by
some of backyard manufacturers who produce non-quality standard pipe mainly due to the
harsh price competition in the market.
1.3 No uPVC-phobia! Why? No backyard product.
However, AB-3P differs from conventional PVC-U since its structure is unique (3 layer) thus
can be easily identified. Furthermore, both AB-3P compound and AB-3P/HI-3P pipes are
patented due to its superior quality and strength as well as latest Nano-technology adopted to
make AB-3P pipe as Anti-Bacteria. Unlike any other polymer pipe, AB-3P Anti-Bacteria Pipe
actively sterilizes water while it passes through the pipe. This technology is the first time in the
world and the technology is proven to be safe by many government authorities including Korea,
Japan, Taiwan, Europe, America etc.
ME-Plas(M) Sdn Bhd owns exclusive license to produce AB-3P pipe in Malaysia and the first
factory in the world who can meets both KS, JIS as well as BS, MS relevant standard.
Therefore, there is no worry to have back-yard product or imitation product since it is very
difficult to imitate even without consideration of patents.
1.4 Long time proven performance.
The high impact resistant strength together with exceptional resistance against corrosion and
chemical attack as well as its unique active sterilization capability which will strongly fight
against bio-film problem makes these pipes ideal for important infrastructure applications such
as NRW as well as sewerage project. Past 15 years experience has confirmed the long term
durability and serviceability of AB-3P pressure pipes.
1.5 Certificate and Registration
AB-3P pressure piping systems meet the requirements of the relevant British and Malaysian
Standards. The pipes are certified and approved by SIRIM and KOTRIC Korea, and also
approved by many States Water Authority and Water Operator in Malaysia.
1.6 System Solution
In addition to AB-3P, AB-DF- the Hot Fusion Bonding Epoxy Coated Ductile Iron Fitting
solution makes perfect system which can be used for Pumping main as well as gravity main
application. HI-3P/AB-3P has been used for pumping main in many Korea water network.
AB-3P pressure pipes are suitable for the various applications such as Potable water net works
and reticulation mains, Industrial process pipelines, Pipelines for pumped sewage and wastes,
Irrigation systems as well as domestic plumbing system. In numerous Korea Water Treatment
Plants are using HI-3P/AB-3P pipe for the benefit of its high chlorine resistance and reliable
performance together with AB-DF system.
1.7 Superior Design
AB-3P has long time proven spigot bell mouth joint together with unique “Supa-tite” rubber ring
design and also user friendly self-locking gland AB-DF design surely guarantee the best joint
quality at site and ensure you the timely completion of project since this jointing method can be
done at any weather condition unlike conventional metal welding or butt-welding or
electro-fusion methodology or solvent cement fusion bonding. AB-DF use long time proven
K-type socket Mechanical joint with enhanced design.
1.8 Color and marking
Standard color is very light oyster grey (In between RAL 9001 and 9002). AB-3P follow
standard MS or BS marking and on client request, we could add some more identification
marking such as “Water” or “AIR” in blue color on the center of pipe with Flow marking. This will
easily help people to identify the type of utility pipe when they excavate the ground.
1.9 Real Lifetime, pipe for our descendant.
The nominal working pressures given for AB-3P pipe are calculated to give continuous use
over 50 years or more. In addition the excellent fatigue strength of AB-3P allows for reasonable
intermittent surges and reductions in flow pressure to be accommodated. Furthermore,
Anti-Bacteria suppress microbial to damage internal wall of pipe unlike any other polymer pipe.
Therefore, AB-3P is the only pipe to maintain its characteristics without changing its internal
diameter and also maintain external surface intact from various attack of microbial erosion.
1.10 Super Fast Construction
Unlike all other welding or fusion bonding based pipe, the unique and error-free spigot joint
design and AB-DF design ensure you the much faster construction. So when you are in need
of fast track construction, do not let pipe laying works delay your other activities by using
AB-3P and AB-DF.
1.11 Residual Chlorine and Bio-Film
Many water operators have a headache to reduce chlorine cost and contents. In summary,
AB-3P absorbs less chlorine than other pipe such as Ductile Iron, Copper, Stainless steel,
HDPE etc. Furthermore, when dormant microbial sticks to pipe wall, it may regrow and form a
bio-film which eventually feed unwanted microbial into the portable water. AB-3P with its
anti-bacteria capacity, microbial can not survive when it sticks to AB-3P pipe wall. Within 24
hours, 99.9% bacteria will be eliminated. FITI JIS Z2801 test report is available on request.
2 AB-3P Properties
The various properties of AB-3P are given in Appendix 1. Followings are other characteristics of
AB-3P pipe to assist you to design the water network.
2.1 Ambient temperature and Pipe pressure rating

AB-3P is generally suitable for service temperatures between 0°C and 60°C. However, if pipe
temperature is above 20°C then the derating factor shall be applied to the working pressure as
in Table 1 thus actual pressure rating shall be adjusted.
Table 1. Thermal derating factors
Maximum Service Multiplication Factor For
Temperature (°C) Pressure Derating
20 1.00
30 0.90
40 0.70
50 0.50
60 0.30
Example)
Nominal PN 9 pipe becomes PN 8.1 at 30 deg Celsius.
AB-3P is generally much stronger than BS or MS requirement thus depending on the

various sizes, AB-3P has certain safety margin.
For example, 15mm PN15 which is the smallest size available for AB-3P can withstand
90 bar in 20 deg Celsius. Therefore, even with 60 deg C, it will easily withstand 2~5 bar
which is normal pressure in domestic plumbing.
For pumping application, water hammering may cause pressure rise-up thus this
abnormal pressure fluctuation shall be also considered. However, AB-3P easily
withstands such a water hammering or pumping pressure fluctuation even in cyclic
frequency without showing any life time deterioration.
Likewise, system approach is very important thus we recommend using AB-DF fittings
and trust block for AB-3P to be used for pumping main application as well as other
application for long-term safe operation.
Other jointing like solvent cement fusion bonding joint or butt welding fusion bonding
usually can not be used for pumping main or where water hammering is frequently
incurred.
Many water authority experienced that the conventional ductile iron fitting with simple
spigot insertion showed unreliable result in water treatment plant thus only use stainless
steel. However, new AB-DF design with proper support can be used everywhere with
great reliability.
2.2 Chemical resistance

Generally speaking, AB-3P is suitable with most strong acids, alkalis and aqueous solutions.
AB-3P is unaffected by water, domestic sewage, or soil. It has excellent resistance against
attack from concentrations of alkalis and acids, aliphic hydrocarbons, except for strong
oxidizing agents at maximum or near maximum concentrations. If hydrochloric or sulphuric
acids are being conveyed in pipes, standard pressure rating can be used even when acids are
concentrated.
However, in the case of nitric acid, it is recommended to go one class higher than indicated. As
for the alcohol or 10% sodium hydroxide, two class higher than indicated is recommended. The
material is not recommended for use with aromatic and chlorinated hydrocarbons, ketones,
esters and ethers. The resistance of AB-3P pipe materials to a wide range of chemicals is
listed in Table 3 below. In addition, careful selection of rubber ring shall be made in case it is
other than the water.
We detail on the appendix a large number of reagent and their effects on AB-3P at 20 deg
Celsius and 60 deg Celsius. It must be understood that no guarantee can be given that actual
result obtained will, in every case, be exactly as shown.
The data should however, taken as guideline only and users are advised to carry out their own
tests when considering specific application or ask ME-Plas(m) to cooperate.
There could be also other alternative solution to be used with not-recommend kind of fluid. In
other words, this list is by no means exhaustive and the fact that a reagent and their effects not
listed, please contact our technical personnel for consultation on the use of chemicals.
2.3 Behavior in Fire

AB-3P does not support combustion and when the source of ignition is removed it is self
extinguishing. The principal doubt expressed with regard to the performance of PVC family
pipe-work during an internal fire is that it would burn away leaving access for the fire to enter
another part of the structure. This has been investigated by the Fire Research Station of the
Building Research Establishment. Special investigation report number 9116, Ad Hoc fire tests
on PVC services in buildings concluded that PVC pipes were found to soften and close forming
a carbonised mass that sealed the void. However as an added precaution we recommend that
where pipes pass through a fire stop that may give access to fire,
2.4 Abrasion Resistance

Due to the extremely low co-efficient of friction of AB-3P pipe it is particularly suitable for the
transportation of abrasive slurries. AB-3P pipe can be used in quarries, sand plants and open
cast mines. Under such conditions, its life expectancy has been established to exceed that of
equivalent steel pipeline by 2 to 3 times.
3 AB-3P/AB-DF Product Features and Benefits AB-3P Pipe
3.1.1 General
With its patented technology, AB-3P with its Nano-Tech skin layer and high tensile center
layer provides the strength and characteristics which single layer pipe can never provide. It
is tough and good quality pipe with good impact strength as well as high tensile strength.
Furthermore, ME-Plas(M) factory is manufactured under an stringent system of inspection,
testing, supervision and control in addition to its famous Total System Solution for water
main and domestic plumbing. Wall thickness of materials are formulated to achieve
strength that exceeds the performance of standards. High quality of finish with smooth
internal and external surface provides low coefficient of flow friction.
3.1.2 Certification and Test Criteria

With SIRIM and KOTRIC certifications, it provide an independent assurance to clients that
ME-Plas(M) products are manufactured under an stringent system of inspection, testing,
supervision and control in addition to its system solution for water main and domestic
plumbing.
In fact, AB-3P pipe is the only pipe which fulfills the strength and property requirements of
Korean Standard KS M 3401 (HI-VP), Japanese Standard JIS K6742 JWWA, British standard
BS 3505 as well as Malaysian Standard MS 628 - Part1 altogether thanks to its superior
quality.
Furthermore, ME-Plas(M) Sdn Bhd has
its own factory standard which is
more stringent than any of above
standard by combining in better
way. However, it shall be take
noted that since this pipe is world
widely patented, no commercial
standard will be specially prepared
for one patented pipe.
When you choose this pipe, there is
also no worry for your contractor to
supply non-standard or bad quality
back yard product since this pipe is
unique and can not be simply
imitated due to its high technology
and patented know-how as well.
So do not simply identify MS 628 or
BS 3505 but identify the brand
name of AB-3P and make sure it is
3 layer glossy with “supa-tite”
unique spigot design.
3.1.3 Unique Spigot Rubber Ring Joint (Bell-Mouth Joint)
AB-3P pipes and its spigot jointing are innovatively
designed and formulated to consistently and reliably
exceed the performance aspects of standards complied,
especially on the hydrostatic pressure. For 80mm and
above, we give unique and extra safety spigot with
supa-tite Rubber ring design for straight joint and for
any other connection, we provide AB-DF, Hot fusion
epoxy coated ductile iron fitting solution which is
manufactured in accordance with BS EN545 with
unique self-locking gland design.
Compared with other rubber ring joint used by uPVC manufacturers, this rubber ring design
shows average 170% higher pipe gripping power. This design has been used in Korea for
more than 15 years and shows its superiority over any other spigot joint thus well accepted
by government.
In addition, we had localized and transferred all design technology to Malaysian prominent
Rubber ring manufacturer and all Rubber ring is SIRIM certified EPDM material.
3.1.4 Anti-Bacteria, Safety Proven Nano-Technology

This technology is also patented and it was test in FITI Korea in accordance with JIS Z 2801
and proved that AB-3P pipe produced in Malaysia sterilizes more than 99.9% of microbial
such as E.Coli within 24 hours. Similar technology is very popular now in many fields such
as food packaging container, refrigerator, kitchenware, water filter and many others. For
more information, please contact our technical team. ME-Plas(M) Sdn Bhd has FITI test
certificate as well as UK Hundington Life Science Test Report for safety test.
3.1.5 Pressure Pipes with Very Low flow friction

With high quality control standard practiced in Korea, all dimensions and performance
surely meet and surpass the requirement of standards. This also guarantees the high
quality of finish with smooth internal bore and glossy and even external surfaces which
eventually provides low coefficient of flow friction. AB-3P has lower coefficient of friction of
0.00001 compared with Cast Iron 0.010 and Ductile Cast Iron Cement Lined Pipe 0.001. the
improved flow characteristics are maintained indefinitely due to non-corrodibility. No
encrustation of the bore means pumping efficiencies are maintained over the years and no
reduction in flow will occur.
3.1.6 Residual Chlorine Absorption

Certain level of Residual Chlorine shall be maintained to provide bacteria free water. So
chlorine absorption by pipe is also very important since chlorine is not cheap chemical.
Furthermore, to achieve required level of chlorine at the end of portable water pipe network,
it is unavoidable to supply overdosed chlorine water to the consumer who is nearer to water
treatment plant. So if pipe absorb less chlorine, overall dosing could be reduced thus
consumer near to water treatment plant also could enjoy less chlorine water.
It is reported by many researcher that Copper pipe absorb the most, then Stainless steel
pipe, Ductile Iron pipe, HDPE pipe and PVC family pipe absorb the minimum chlorine.
Furthermore, AB-3P also further assists to eliminate more microbial which may exist in the
supplying water.
3.1.7 Bio-Film
There are thousands of reports about bio-film formation on the portable water pipe wall.
Even if polymer pipe has minimum slime and no scale unlike other metal
pipe or metal pipe with cement lining, bio-film is found in slime and when
the dormant microbial stick on slime and re-grown then forms bacteria
consortium after 2 to 3 months. Surprisingly, there could be even some bacteria with
chlorine resistance. This has been a serious headache for water infrastructure operator. To
eliminate this, they used to dose more organic sterilizer and this organic sterilizer like
chlorine, the more they dosed and then all metal based pipes corrode even faster. AB-3P is
the only pipe where slime contact water pipe wall, bacteria can not grow thanks to its latest
patented Anti-Bacteria Nano-Technology. AB-3P pipe Anti-Bacteria functionality and
effectiveness is tested by FITI Korea with JIS Z 2801 using E.Coli bacteria and shown the
capability that 99.9% of Bacteria is exterminated after 24 hours.
3.2 AB-DF Epoxy Coated Ductile Iron Fittings for Heavy Duty Application
3.2.1 General
AB-DF jointing is long time proven mechanical jointing method
which is same as mechanical coupling but with some additional
easy and error free installation feature using innovative gland
design.
The AB-DF Series, joint plain end AB-3P pipe to flanged valves,
fittings, pumps and other equipment with integral flanged ends.
There is no need for threading, welding or grooving the pipe end
since AB-DF has built in thrust restraint.
The AB-DF is designed to eliminate the problems inherent
with pre-fabricated, pre-engineered piping systems. With
the AB-DF system, flanged piping can be fabricated on the
job site, eliminating the need for off-site suppliers and delays
caused by inaccurate dimensional details.
The working principles of the AB-DF are relatively simple.
Cut the pipe to the length required. Slide the flange over the
plain end pipe and follow it with a standard mechanical joint
gasket and polymer washer and Lock ring (provided with
Gland). When the AB-DF is brought to mate against the
existing flange and the flange bolts are tightened, a
compression type seal is created against the mating flange
and onto the pipe surface. End restraint is provided when
the set screws around the hub of the AB-DF are tightened. AB-DF Gland pioneered this
time and field proven method of flanging pipe. Similar Gland Adaptors have been in
continuous use in thousands of installations for more than 15 years. In addition, AB-DF
Ductile Iron Fitting have passed the most stringent of laboratory tests with third party
certification of performance.
AB-DF offers the most complete line of adaptor flanges in the industry from 80mm through
400mm pipe sizes. Specify the leader in flange adaptors for your next project . AB-DF, Self
Locking Gland Design.
3.2.2 Certification complied to BS/EN 545

Ductile iron fittings & accessories are complied with EN 545:2002, are constructed in such
way so that they can be attached to the matching component which the dimensions &
tolerances to BS/EN 545.
This ensures the leak-tightness interconnectivity between all component, in order to
provide adequate joint performance required over their operating life.
3.2.3 AB-DF GLAND DESIGN – ADVANTAGES

z Job Site Fabrication Using Plain End Pipe:
AB-DF Gland eliminates the problems of pre-engineered, pre-fabricated piping
systems. Pipe fabrication can be performed at site using plain end pipe, a pipe
cutter and a wrench. No threading, welding or grooving is necessary. The AB-DF
Gland eliminates the need to rely on off-site fabricators and machine shops. It is
ideal for projects that involve retro fitting or renovation of existing piping systems.
The AB-DF Gland keeps the project moving…… DOWN TIME SAVINGS are
considerable.
z NO MORE worry about Expansion and Contraction!
Unique k-Type socket absorb all expansion and contraction even with exposed to
direct sunlight. UNLIKE SOLVENT CEMENT TYPE JOINT fittings, AB-DF rubber
ring smoothly wrapping around pipe thus pipe is free to expand and contract.
Furthermore, even with water hammering or vibration or deflection, this design
gives superb performance which surpasses any other design available in the
market. To make perfect performance, make sure to make proper strong support
for exposed application and cast concrete anchor block for underground
application as DI fittings.
z Eliminates Bolt Hole Alignment Problems:
AB-DF Gland Adaptors can bee freely rotated BEFORE AND EVEN AFTER the
flange bolts are inserted then align it properly and tighten it. This facilities bolt hole
alignment with the facing flange. Pre-fabricated piping systems do not offer this
installation advantage.
z There is no bolt like us:
AB-DF gland comes with Ductile Iron Hot Dip Galvanized Bolt which offers 170%
more tensile strength than normal Mild Steel Bolt. Furthermore, it comes with hot
dip galvanized thus life time is semi-permanent. In addition, to make installation
easier, innovatively design L-shaped head is automatically .engaged in the gland
hole and seat properly on edge of main body thus fitter need only one spanner to
tighten M18 nut. All bolt size is same regardless of pipe diameter but only numbers
of bolt, nut & washer are different depending on the pipe size. This standardized
bolt size eliminated workers error as well.
z Deeper Insertion and more option:
Compared to original Korean design, this design has a few more enhancement. It
has deeper insertion length thus provide more secure engagement between pipe
and fitting. It also has smoother inner bending to provide better water flow. We also
offers you more versatile coating option such as cold epoxy coating for special
emergency project where you need non-standard size. We also offers more
prestigious and expensive Rylsan Nylon Hot Fusion Bonded Epoxy Coating which
provides you stronger bonding to metal body and better sea-water resistant and
anti-abrasion than the ordinary Hot Fusion Bonded Epoxy Coating.
z Allows for Pipe misalignment:
Unlike conventional threaded or welded gland, the AB-DF Gland will allow for pipe
deflection during installation. This means the AB-DF Gland can “make the
connection” when other methods can’t.
z Built-In End Restraints:
The AB-DF Gland offers built-in end restraint with polymer washer and Lock Ring
grip. No tie rods or similar forms of anchoring is necessary.
z Future Maintenance Capabilities:
When future maintenance is required on gland equipment such as meters or
valves, the AB-DF Gland can be easily dis-assembled and slid back on the pipe.
This allows for removal of the gland equipment. When the equipments are to be
replaced, simply drop it and re-install the AB-DF Gland. Threaded and welded
flanges do not offer this feature.
3.2.4 AB-DF GLAND DESIGN – Exposed Application

In practice, no problems have been reported even under exposed application like Pumping
Station once properly supported. But for added security, we recommend the following:
z Wiring of set screws to prevent loosening.
z Apply ‘Loc-Tite’ to the set screws after they are tightened.
4 Pipeline design
4.1 Hydraulic design
The capacity of flow in a pipeline can vary due to various
factors, which include the roughness of pipe bore,
influenced by the growth of scale and slime, roughening
due to abrasion and joint imperfections / fitting types and
configurations. Especially, it is well known fact that any
cement lined pipe is extremely vulnerable for scale and
also abrasion thus as time goes by, its coefficient value
drop drastically.
The flow data of AB-3P can be obtained from the charts

below. (Head Loss Nomogram)
Yet, for engineers who like to work with other formulae, the friction co-efficient of AB-3P pipes
are as below;
Absolute roughness For calculation of friction coefficient
Formula Up to size 300 Above 300
Colebrook 0.00001 m 0.00001 m
Darcy Weisbach - 0.03 ~ 0.06
Hazen-Williams 140 ~ 150 150
Flow capacity is calculated by using the Colebrook White Transition Equation and it is assumed
pipes are full bore discharge and velocity calculation. This equation takes into account, liquid
viscosity and pipe roughness, and is recognized as being one of the most accurate in general
use but requires an iterative solution. This equation also enables user to establish the
relationship between friction loss, discharge and velocity.
V=-2 x SQRT(2gDS) . log(k/3.7D + 2.51√ /D x SQRT(2gDS) where;
V = mean velocity in m/s

S = hydraulic gradient in m/m
D = pipe internal diameter in meters
g = gravitational acceleration, taken as 9.81 m/s
-6
√ = kinematic viscosity, taken as 1.01 x 10 m/s (at 20 deg C, 1.146 at 15 deg C)
k = pipe wall roughness, taken as 3x10-3 m
This value of the equivalent roughness coefficient "k" assumes the AB-3P pipeline is straight,
clean and concentrically jointed without fittings. Possible values ranging between 0.003 to
0.015
Type of pipe New After 50 years Remarks mm.
AB-3P 150 140
Any pipe with Cement Lined 150 110 Scale factor not
Inside (Smooth bore) considered
Any pipe with Cement Lined 140 90 Scale factor not
Inside (Rough bore) considered
Steel Pipe without cement 140 40
Cast Iron without cement 130 40
Hazen Williams coefficient “C” for various 100mm pipes are listed for your information.
Table 2. Hazen Williams coefficient “C” for various 100mm pipes
4.1.1 Flow Calculation
For AB-3P flow calculation. You may use Hazen Williams Formula.
Q=AV
V= 0.84935 CR0.63I0.54
A=3.14D2 / 4
Q=0.27853 CD2.63I0.54
Where;
Q= Flow (m3/sec)
A= Pipe Cross-sectional Area (m2)
V= Velocity (m/sec)
C= Coefficient = 150
R= D/4 (m)
I= Water Route Slope (h/L)
D= Internal Diameter of Pipe (m)
.
4.1.2 Head Loss Calculation
Except head-loss by friction, all other loss factor can be disregarded since it is negligible
once total length of pipe become long.
hf= f L V2 / D 2g
f= 133.7 / D0.167C1.85V0.15
Where;
hf= Head-loss (m)
f= Pipe friction coefficient
g= gravity (m/sec2)
n=0.01.
4.1.3 Pipe INTERNAL Diameter Selection

Calculate water flow required and also slope.
ID=1.6258C-0.38Q0.38I-0.0205.
Example)
Want to deliver 30,000 m3/day from reservoir (Ground level=160m) to town (GL=100m).
The distance is 2 km. Calculate ID.
Q=0.347 m3/sec
I=60/2000=0.03
D=1.6258 x 150-0.38 x 0.3470.38x 0.03-0.0205 = 0.332 m (ID)
So in the Appendix 2 AB-3P Internal Diameter, Out-Diameter, Thickness Quick Reference
Table, 400mm PN12 is good enough and safe for this application.
4.1.4 Pressure class selection

The nominal pressure rating of a AB-3P pressure pipe is indicated by the PN, followed by a
2 number indicating the nominal pressure capacity.
For example, a PN12 pipe has a pressure capacity of 12bar at 20°C. This pressure should
not be exceeded through out the pipeline by the maximum operating pressure including
water hammer pressure surcharges.
See also Section 4.1.2 and 4.2 respectively for fatigue and structural considerations.
During the design, combined air release and anti-vacuum valves must be installed at local
high points in any section of a pipeline, so as to maintain full flow and prevent vacuum
conditions from occurring.
4.1.5 Water hammer surges and cyclical effects
Water hammer occurs in a pipe line when there is sudden fluctuation of flow caused by the
rapid start and stop of pump or opening and closing of valve.
Water hammer can cause a lot of problems such as damaging equipment, pipe bursting,
operation tuning difficulty and reduce system capacity.
Water hammer effects in AB-3P material is considerably low when compared with iron, steel
and concrete due to the much lower modulus of elasticity.
Where repeated pressure variations occur in AB-3P pipeline, say in the case of a pump
switching on and off in a rising main it may be necessary to consider the effect of fatigue
over the life time of the pipeline.
Design of pipeline should take into account the frequency of pressure fluctuations (cycles)
during the life of the pipeline and the amplitude of the pressure change between the
maximum and minimum steady state operating pressures plus water hammer effects.
This value when divided by the derating factor given in Table 4 should not exceed the
nominal pressure rating of the pipeline components. In practice the pressure changes in
water reticulation systems are seldom of sufficient amplitude and frequency for fatigue to
affect pipe class selection, but they can be an important consideration for pumping
systems.
AB-DF ductile iron fitting does not shows any problem on this aspect of cyclic fatigue
derating.
Table 3. Fatigue derating factors
Total cycles Fatigue derating factor, f
100,000 1.00
500,000 0.62
1,000,000 0.50
2,000,000 0.50
5,000,000 0.31
Note: A cycle is defined as one combined pump stop and start operation unless
an allowance is considered necessary to allow for attenuation of the surge wave.
In this case the cycle count should be twice the number of start/stop operations.
Examples:
1) A main pumping line is operating at the pressure of 7 bar. At the start and
stop of pump, the pressure fluctuates between 4 bar and 10 bar. The pump
start/stop at 3 times and hour and the design life is 50 years.
Therefore;
The pressure amplitude = 10 – 4 = 6 bar The whole life cycle = 3 x 24 x 365 x
50 = 1,314,000 From Table 4, the derating factor = 0.5
The minimum pressure rating (P) of the pipeline components (pipes, fittings,
valve & etc) is;
P = 6/0.5 = 12bar. Hence, a PN12 rated component is required at the operating
pressure of 7 bar.
However, for light application in domestic plumbing, Paling® PVC fittings present a
problem worthy of special consideration. Complex stress patterns in fittings can 'amplify'
the apparent stress cycle. An apparently harmless pressure cycle can thus produce a
damaging stress cycle leading to a relatively short fatigue life.
This factor is particularly severe in the case of branch fittings such as tees, where
amplification factors up four times have been noted. The condition can be aggravated
further by the existence of stress cycling from other sources, for example bending stresses
induced flexing under hydraulic thrust in improperly supported systems.
Prudence therefore dictates that a suitable factor of safety be applied to fittings in
assessing class requirements. It is recommended that the following factors be applied to
the design dynamic pressure cycle for fittings:
Tees equal Dx3/4D Dx1/2D Dx1/4D

Safety Factor 4 3 2 1.5
Bends 90°short 45°short 90°long 45°long
Safety Factor 3 2 2 1.5
Reducers Dx3/4D Dx1/2D Dx1/4D

Safety Factor 1.5 2 2.5
Example:
A golf course watering scheme is designed to operate at 0.70 MPa. Balanced
loading will ensure no pump cycling during routine watering. However, the
system is to be maintained on standby with a jockey pump for hand watering
purposes and this will cut in and out at 0.35 and 0.75 MPa. With normal usage
and leakage this may occur every half hour on average for twelve hours a day.
A twenty-five year life is required.
The total dynamic cycle is 0.4 MPa. The total life cycles predicted is 24 x 365 x
25 = 219,000. Referring to the chart, load factor is 0.8.
Therefore, P = 0.4/0.8 = 0.5 MPa (In this case, PN9 pipe is suitable)
For fittings;
Equal Tee; P = 0.4/0.8 = 0.5 MPa x Safety Factor = 0.5 x 4 = 2 Mpa Elbow; P =
0.4/0.8 = 0.5 MPa x Safety Factor = 0.5 x 3 = 1.5 Mpa
A PN15 equal tee may not have an acceptable life in this system, only PN15
elbow is suitable.
Solution: Reduce the dynamic range or reduce the frequency or the periods on
standby.
Water hammer can be minimized by applying many control devices in the system. The
most influential parameters in selection of these devices such as air vessel, discharge tank,
surge tank and suitable location can be calculated with qualified consultant. The guideline
data is also available on request.
Also take note that above calculation does not consider extra strength and safety which
AB-3P can only provide. Therefore, with above design criteria, you will have minimum 10%
more safety than other uPVC pipe. But we still recommend following above criteria since it
will give more reliability to the whole system.
4.2 Structural Design

AB-3P are classified as "flexible" pipes, which means they have the ability to deform or deflect
diametrically within specified limits without structural damage or impairing the performance of
the pipes.
The external soil and live loadings imposed on flexible pipes may cause a decrease in the
vertical diameter and an increase in the horizontal diameter of the pipe. The horizontal
movement of the pipe walls in the soil material at the sides develops a passive resistance within
the soil to support the external load. Hence, the pipeline performance is influenced by the soil
type and density. The higher the effective soil modules at pipe depth, the less the pipe will
deflect.
Allowable deformation is up to 9% of its diameter and will not affect the pressure rating of the
pipe. A complete design approach is covered in BS EN 1295-1.
4.2.1 Minimum Cover Height

A minimum cover height of 450mm to the top of the pipe should be adopted for areas
without traffic loading. Under paved roadways the minimum cover height is 600mm or
750mm in unsealed roadways, and pipe embedment material should have a minimum
compaction Density Index of 65%. After pipes are laid and centered in the pipe trench, the
embedment material should be compacted in 80-100mm layers to the specified density.
The embedment should continue above the pipe to provide protection from the backfill.
That is a height above the pipe of 80-150mm may be required.
4.2.2 Thrust block for fittings

Where a pressurized pipeline system utilizes rubber ring joints, thrust will develop at
changes of size or direction of the pipeline such as at tees, elbows, reducers, valves and
closed ends. In buried installations, fittings shall be restrained by concrete blocks to be cast
at site. These thrust blocks should be formed and sized to effectively transfer the resultant
thrust at the fitting to the adjacent soil. The soil type and depth will influence the efficiency
of the thrust transfer. Thrust blocks must be of certain dimensions and shaped to distribute
the force to a plane surface of the undisturbed soil, normally perpendicular to the imposed
load. The interface area should be determined and the following equation can be used:
A = T/b x f 2
Where; A = area perpendicular to force (m )
T = hydrostatic thrust (kN) developed by the pipeline pressure on fittings
b = soil bearing capacity (kPa)
f = factor of safety
4.3 Above ground Installation

ME-Plas(M) AB-3P Piping system is suitable to be installed above ground or exposed. The
following measures however, are required to ensure the serviceability of the system;
4.3.1 Protection against ultra violet (UV)
AB-3P pressure pipes can be used above ground since it is quite strong against UV thanks
to its UVA additives which is only included in skin layer and also Nano-Silver implement
additional benefit. However, to secure its longer 50 years lifetime performance, one of the
following is recommended whichever is preference of end user.
z Use thin wall economical drainage pipe of similar OD and cut longitudinally and cover
the pipe. This thin wall pipe maybe bad quality and change its color or whatsoever but
it will never affect internal AB-3P. This is the best and economical method for tropical
country.
z Applying acrylic paint over the pipes.
z Use thin wall mild steel pipe or tin plate and paint it as usual. Even very thin pipe does
not really matter since it is simply cover of the pipe only.
z In the four season countries, they need to be well prepared for the winter time, they
normally use Styrofoam and tin sheet casing or similar to insulate pipe to protect
portable water from freezing. In such a case, it is completely safe from any UV.
4.3.2 Heat Expansion & Contraction

Note that this is not necessary when using AB-DF and Bell-mouth joint. Only applicable
when you decide to use solvent cement joint.
The expansion and contraction of plastic pipe is a function of the change in average
temperature of the pipe wall. This temperature depends on internal and external
environmental temperatures and whether the environments are gaseous (air) or liquid.
The most common case is a pipe conveying liquid surrounded by air.
The following simple equations may be used for calculation of expansion or contraction
under these conditions:
∆TL = Maximum temperature change in pipe contents

∆TA = Maximum temperature change of external air
∆T = Change in average temperature of pipe mid-wall
∆L = Change in length of pipe work section under consideration
k = Coefficient of linear expansion of pipe material, for AB-3P = 7 x 10–5 mm/mm/°C
L = Original length of pipe
To calculate pipe wall temperature change, use the equation
∆T = 0.65 ∆TL + 0.10 ∆TA
Using value of ∆T calculated, then calculate expansion using the equation
∆L= ∆T Δ L.k
4.3.3 Pipe movement
Note that this is not necessary when using AB-DF and Bell-mouth joint.
Only applicable when you decide to use solvent cement joint.
To accommodate the expansion and contraction without stressing the pipe, expansion loop
may be constructed with suitable length of unrestrained pipe (free leg length) as shown in
the graph below:
Example:
Determine the free leg length required to accommodate a change in length of 20 m of
90mm diameter pipe work caused by an increase in contents temperature from 20°C to
40°C, with the external air temperature also increasing from 5°C to 25°C.
1. To calculate pipe mid wall temperature change (∆T) apply the equation:
∆T= 0.65 ∆TL + 0.10 ∆TA Therefore ∆T = 0.65 (40–20) + 0.10 (25–5) i.e.
∆T = 0.65 Δ 20 + 0.10 Δ 20 = 15°
Note: The common error when calculating ∆T is to use extremes of temperature, in this
case 5°C for air and 40°C for contents. 35°C would then be used for ∆T in the next
calculation instead of the correct 15°C which would give more than double the true value.
2. To calculate expansion (∆L)
∆L= ∆T x L x k therefore ∆L = 15
x 20 x 7 x 10–5 mm/mm/°C =
0.0210m = 21mm
3. To calculate free leg length
using the value of ∆L/2, draw a
horizontal line on the graph from
the vertical scale to meet the 3in
or 90mm pipe gradient line. Drop
a perpendicular from the
intersection point to the
horizontal scale. The figure
obtained is the free leg length of
loop required, which in this case
is 1.03m.
As a rule of thumb, AB-3P pipes
will expand or contract by
0.6mm/metre for every 10°C
change in pipe wall temperature.
4.3.4 Exposed Pipe support
Support should not restrain the longitudinal movement of pipes.
Where unyielding material like steel is used to support pipes, a
suitable compressible material (ie. rubber), with a thickness of
3mm is used between the pipe and the clamp.
If AB-3P is installed in the vibrating area or similar environment,

you can still consider Optional Ultra Grip. But also be reminded
that OUG is raking pipe surface thus more safety factor is
required.
The recommended distance between supports, vertical and
horizontal, is tabulated below:
Table 5. Recommended Distance of Pipe Support

Distance between support for various water
temperature (PN12)
size vertical
horizontal pipes (mm)
(mm) (mm)
20 deg C 30 40 50 20 to 50
15 850 700 500 400 900
20 900 750 550 500 1000
25 1000 850 650 570 1200
32 1100 1000 800 700 1400
40 1250 1150 950 820 1600
50 1400 1300 1100 970 1800
65 1500 1400 1200 1070 2000
80 1650 1550 1350 1200 2200
100 1850 1750 1550 1370 2400
125 2000 1900 1750 1570 2450
155 2250 2150 2000 1850 2500
175 2400 2250 2200 2000 4400
200 2750 2500 2300 2100 4600
250 3100 2850 2600 2450 5200
300 3550 3300 3000 2700 6000
350 4000 3800 3500 3100 6000
400 4300 4200 4100 3500 6000
5 Installation
5.1 Transportation, Handling and Unloading
AB-3P pipes should only be transported on vehicles with a flat bed that provides adequate
support along the full length of the pipe. The bed of the vehicle must be thoroughly checked
before loading to ensure that it is free from sharp material that may damage the pipes. Where
side supports are required they should be smooth and not more than 1.5m apart. An
unsupported overhang at the rear of the vehicle should not exceed 1m. As with storage the
packs of pipe should be loaded with the heaviest at the bottom.
Pipe that arrives on site damaged should not be used and the incident should be advised to
ME-Plas(M) immediately.
AB-3P pipes are light (about 1/7 of the weight of Mild Steel Cement Lined Pipe) and easy to
handle. Installation time is very fast with bell mouth rubber ring joint and simple AB-DF design.
Nevertheless, careless handling may cause unnecessary damage.
Important notice for unloading:
z Do not throw from lorry. (Rolling properly, if you do not have forklift!)
z Do not unload by sliding from the tailboard of lorry
Pipes and fittings should not be dropped or thrown onto

sharp objects which could inflict deep scratches. AB-3P
pipes should not be allowed to slide across sharp edges.
During construction storage areas should be selected
which are free from surface irregularities such as stones,
or other sharp projections.
When you do not have any unloading equipment or
means, when unloading, if pipe is not bundled, you may
still unload it horizontally rolling down to the ground. But
put three shock absorbing material such as used tire at 2
meters interval. Then also put smooth timber or polymer
pipe to give maximum 45 degree slope to the ground.
When pipe rolled down, it shall not hit any sharp edges
or metals around. Then when it rolls down, it will bounce
to tire and seated to ground safely. However, for AB-DF
and fittings, never throw or roll down. It shall be gently
unloaded using either equipment or manually. AB-DF is
delivered with proper wrapping material to protect
epoxy coating. Do not tear it off until you install it at site.
5.2 Storage
AB-3P pipes may distort under high loads. Therefore stack heights should be kept to a
minimum for long term storage. (2 meters or below)
At elevated temperatures pipes may bow due to uneven heating of individual pipe lengths.
Where this may be a problem during installation they should be protected from direct sunlight
immediately prior to use. So we recommend stacking in # shape and also do not compress
directly on to both of the bell mouth spigot jointing end. i.e. Bell mouthed pipes should be
stacked in layers with sockets placed at alternative ends of the rack, and protruding, to avoid
uneven stacks and distortion. The sockets should not be allowed to carry loads. We also
recommend storing AB-3P with proper cover to prevent UV as well as dust. AB-3P is strong
against UV effect but providing proper cover is always better. Also excessive heating may
deteriorate rubber ring. Even though this rubber ring is EPDM and the one of the best quality,
rubber ring is weaker than pipe itself thus proper ventilation to keep the pipe less hot is always
wise choice.
Important Notice
z Do not stack more than 1 meter if stacked in parallel.
z Do not stack more than 2 meters if stacked in # shape. (Best recommendation)
z Cover when you want to store for long time.
Right is ideal storage of any polymer pipe. You can also nest small size pipe in the big size pipe.
However, when you stack like
right figure as parallel manner,
do not stack more than 1 meter
high.
When equipment such as fork
lifts or cranes is used on bundles,
adequate spreader and lifting
bars should be provided.
Wire slings must be kept clear of
the pipes. When unloading
alongside excavated trenches, it is recommended that pipes be placed on the opposite side of
the trench from excavated material.
AB-DF Fitting Rubber rings, Polymer Ring and Washer, jointing fluid, solvent cement and
priming fluid should be stored under cover until pipe installation starts.
5.3 Fabrication, Cutting

In case AB-3P pipe should be cut, use a fine
tooth panel saw. It is important that the cut
should be square and to this end a mitre box
or similar device is recommended. If this is
not available a square cut can be obtained by
using a piece of paper wound around the pipe
as shown in figure. The outside edge of the pipe end should be chamfered to approximately
15° so that at least 50% of the wall thickness is removed at the leading edge. After cutting, a
chamfer of this nature is essential for both solvent cement and rubber ring seal joints. a rasp
or file can be used for this operation.
Cutting the pipe Square

z Using a sheet of paper with square edges, wrap it round the pipe.
z Ensuring that the paper is tightly wound and ends are square, cut along edge of paper
After cutting, when you insert to bell mouth joint, please make sure to make champering at
spigot end to make nice insertion to other bell mouth. You may use pile or grinder and make 15
degree slope at the end.
5.4 Installation: Underground Trench Construction

It is very important to take note that AB-3P pipes shall be immediately backfilled except joint
point exposed for testing verification. If this is not possible, cover the pipe even a little bit with
sand or similar before testing. During the installation of pipe, footing and sand bedding are vital
importance for higher safety of pipelines.
The reasons are as follows.
z Weaken the stress acting upon the pipe to increase its safety.
z Prevent the pipe from moving at the flowing of water to impede generation of heavy forces
which may temper the pipe.
z Protect the pipe to prevent occurrence of external damage by stone or rock and generation
of heavy stresses, and
z Form a uniform footing for longer retention of piping function.
z Execution of works in accordance with the following specification is therefore imperative.
Trenches should be
constructed in
accordance with the
local authority
requirements. They
may be as narrow as
possible at the
spring line of the
pipe. The detail
design of trench can
be obtained from BS
EN 1295-1.
Adequate width of trench should be provided for compaction of the embedment material in the
side support zone.
Recommended Trench
Minimum Width (W)
To make easier reference, following is recommended dimension on
the right Table 6. Pipe Size W (mm)
15 42
For minimum cover over the pipe (H), please refer to as follows; 20 52
- Private way No vehicle loading: 300 mm 25 69
- Private road, Paved: 600 mm 32 85
- Public Road: 900 mm 40 98
- Heavy Traffic road: 1200 mm 50 122
65 152
Note: Final depth shall be decided with Consulting engineer in
80 178
accordance with local regulation and practice.
100 315
125 425
5.4.1 Bedding material 155 460
Unless otherwise specified, following material is recommended. 175 477
- Sand free from rock or hard and sharp objects which is larger 200 500
than 13.2mm sieve. 250 550
- Crushed stone with approved grade which is normally smaller 300 615
than 14mm. However, AB-3P is not easily punctured or 350 655
cracked unlike other polymer pipe but it is always discrete 400 700
not to have sharp material under the pipe.
- Compaction, as well as the type of natural soil of the trench wall, are important in
determining the ultimate performance of AB-3P. The trench bottom should be as
smooth as possible and to grade.
- Embedment material such as bedding, side support and overlay material should be of
non-cohesive granular material. Pipes should not be buried in contact with soil particle
sizes larger than 5% of diameter, with 20mm as maximum.
- Remove temporary supports such as bricks or timber be left under or in contact with
pipes. If the excavated material is not granular or friable, or does not comply with the
project specification, then suitable embedment must be imported.
- Jointing should be excavated in the bedding for pipe sockets to ensure the pipes are
evenly supported along the full length. In the absence of any specification and if the
pipe Classes are PN9, it is important that only non-cohesive or granular embedment be
used. Careful attention to the placement of embedment material to the specified
relative compaction with an absence of voids is recommended.
5.5 Installation: Above Ground Exposed Construction
5.5.1 Protection against ultra violet (UV)
AB-3P pressure pipes can be used above ground since it is quite strong against UV thanks
to its UVA additives which is only included in skin layer and also Nano-Silver implement
additional benefit. However, to secure its longer lifetime performance, following is
recommended whichever is preference of end user.
z Applying acrylic paint over the pipes.
z Use thin wall economical drainage pipe of similar OD and cut longitudinally and cover
the pipe. This thin wall pipe maybe bad quality and change its color or whatsoever but
it will never affect internally protected AB-3P.
z Use thin wall PE Jacketing or tin plate with paint.
z In the four season countries, they need to be well prepared for the winter time, they
normally use Styrofoam and tin sheet casing or similar to insulate pipe to protect
portable water from freezing. In such a case, it is completely safe from any UV.
5.5.2 Heat Expansion & Contraction & Pipe movement

Only applicable when you decide to use solvent cement joint. It is not necessary when you
use bell mouth joint and AB-DF fittings!
To accommodate the expansion and contraction without stressing the pipe, expansion loop
may be constructed with suitable length of unrestrained pipe (free leg length) as shown in
the graph below:
However, even if it is exposed to direct sunlight, when you use supa-tite rubber ring joint
in the run and using k-type socket AB-DF, it absorb all mild natural pipe movement or heat
expansion and contraction thus this looping is NOT necessary.
5.6 Jointing using “Supa-Tite” Rubber Ring Joints (Above and under ground)
ME-Plas(M) AB-3P pipes are supplied with “Supa-tite” rubber ring, pre-assembled at factory.
Approved lubricant should be used when jointing pipes to ease the insertion of spigot and is
supplied together with pipes.
5.6.1 Jointing Procedure (Factory

Rubber ring inserted Pipe)
The rubber ring joint should be assembled as
recommended by the pipe manufacturer. It is
usually pre-assembled at factory.
z Take out the end-cap on Bell mouth
(female pipe) side. Please return cap
to water authority or properly dispose
it to avoid eyesore complaint.
z Check inside of belled parts and if there is any dirt, clean the Rubber Ring (but do
not pull out, clean as it is seated), the socket or the coupling interior, with a rag to
remove any dirt or foreign material before assembling.
z Apply approved AB-3P Lubricant on surface of Rubber Ring.
z Align it straight to chamfered spigot male pipe to belled pipe.
z Take off cap of chamfered male pipe.
z Clean the surface of male pipe for insertion.
z Apply lubricant from end to the HALF of insertion black marking line
z Align and push gently with jig for small size, for big size use excavator and push
other end of pipe using timber or similar material not to damage the pipe end.
z Make sure marking line is visible and well bordered with belled parts. If it is farther
than 5 mm, it is not properly engaged. Push a bit more.
5.6.2 Jointing Procedure (Site Rubber ring insertion)

In some special application, the EPDM rubber rings could be supplied separately in cartons.
If you need to install at site, in any cases;
z Clean the ring, the socket or the coupling interior, especially the groove area and
the spigot area with a rag or paper to remove any dirt or foreign material before
assembling.
z Inspect the ring, pipe spigot chamber, ring groove and sealing surfaces for
damages or deformation.
z When inserting the rubber ring, make it like heart shape and seat it into groove.
z Use only “Supa-Tite” rubber rings which are designed for AB-3P and supplied with
the pipe. Insert them as recommended by the ME-Plas(M) sdn bhd.
z Use only the lubricant supplied by ME-Plas(M) Sdn Bhd
z Remained procedure is the same as above.
5.6.3 Various Method of Assembly for AB-3P Bell-Mouth Pipe

z Crowbar method:
Complete entry of the spigot into the socket maybe obtained by pushing with crow-bar
or suitable level against the face of the socket of the entering pipe.
z Fork Tool Method:

For joint 80mm to 200mm, fork type tool may be used for assembly. The fork is placed
over and behind the socket of the last pipe laid. A wire rope sling is wrapped around the
spigot to be joined.
z Trench Excavator method
Where trench is prepared using excavator, this machine could be used for pushing the
pipe into the bell mouth. This method is very effective for large diameter pipe. Please
use timber to the edge of the pipe so that excavator bucket does not directly contact
the pipe.
z Wire Rope Puller method

For joint above 200mm, a wire rope or chain puller can be used as shown in diagram.
The puller is normally available in hardware shop.
AB-DF Ductile Iron Fitting Joint with AB-3P pipe usually does not need complicated tools.
It is mechanical joint type with innovative gland design. So pipe insertion is easy and does
not need any complicated tools.
5.7 AB-DF Epoxy coated Ductile Iron Fitting Installation
AB-DF jointing is mechanical jointing method which is same as mechanical coupling but with
some additional easy and error free installation feature using innovative gland design.
5.7.1 Assembly Procedure

5.7.1.1 AB-DF, Gland Design
z The most important part of AB-DF is Gland.
z Gland always comes with EPDM Rubber ring and
Polymer Lock Ring and Polymer Washer. Check 4 items
are not missing.
z Also check required numbers of M18 L-Shaped Bolts,
Nuts and Washers are with you.
z Make sure to bring suitable M18 spanner. (Wrench size
27mm)
z Place AB-DF at jointing part.
z Take off wrapping material just before joint. Insert
pipe to stop notch and pull out 5 mm and draw line to
outside of pipe.
z Insert Gland to pipe.
z Insert Rubber ring for AB-DF (NOT “supa-tite”!).
z Insert Polymer Lock Ring
z Insert Polymer Washer
z Push pipe into the AB-DF (No need lubricant)
z Tighten gland with L-shaped nut and washer using
spanner for M18 nut. (Wrench size 27mm).
z Check that bolt head is automatically engaged inside of
gland bolt hole and hook on the edge of fitting body.
z Tighten the nut a 80% only. (a bit loose to turn gland)
z Turn gland.
z Tighten the next nut.
z Repeat this until you tighten all the nut/washer/bolts
required.
z Align bolt position of gland to make easier final
tightening considering your working space.
z Tighten fully. But make sure that when you tighten one
bolt, the next bolt shall be opposite angle across the pipe center. It is same
principle when you tighten car tire bolt when repairing flat tire.
z Make sure that all 4 components are installed.
5.7.1.2 AB-DF Flange Connection Part
Some of the AB-DF fittings are designed to match with other devices such as valve or
Mild Steel Fitting/Pipe/Ductile Iron Fitting etc using mechanical flange such as Flange
Adaptor, Flange T Joint, Flanged blank-end (Endcap) etc. The most important part is
proper tightening when it comes to flange type connection.
5.7.1.2.1 Required equipment:
z Gasket Bolt size
Spanner size
z Bolts & Nuts (m m across flats)
M 16 24
z Torque Wrench
M 18 27
z Oil / grease M 20 30
z Spanner / Socket M 24 36
(table) M 27 41
M 30 46
5.7.1.2.2 Procedure M 33 50
M 36 55
As with all flange M 39 60
assemblies, rubber gasket M 45 70
and faces of flanges must M 52 80
be free of sand, grit, grease or other matter.
Hold the gasket in correct position on a clean flange face align until faces of
both flanges meet.
Insert the upper and lower bolts, then hand tighten the nuts. Insert the
remaining bolts and then hand-tighten the nuts.
Tighten the opposite sets of bolts in the sequence, ie. start with bolts of the
upper and lower sides of the flange, followed by the right and left bolts.
Tighten all sets of bolts around the flange by achieving the recommended
bolt torque. Check and if necessary, re-tighten the bolts. Installation is
complete.
PN 16 Flanged
5.7.1.2.3 Bolting Torque Nominal Size
Bolting Torque
The chart indicates the approximate bolt DN Nm
torques required to seal flanged joints against 80 70
100 80
internal pressure. 150 120
Bolts must be tightened in the correct sequence 200 115
with sufficient circuits to ensure that the 250 165
300 180
required bolt torque is achieved on each bolt.
350 175
If your contractor does not have torque wrench, 400 220
please train them with normal spanner and
check with your torque wrench until he is familiar with the strength to apply with
spanner to achieve right torque value.
5.7.1.2.4 Bolting Details
The chart indicates the approximate bolt torques required to seal flanged joints
against internal pressure.
Nominal PN16 Flange
Diameter Length
No Dia
DN mm
80 8 M16 65
100 8 M16 65
150 8 M20 70
200 12 M20 70
250 12 M24 80
300 12 M24 85
350 16 M24 90
400 16 M27 95
5.7.2 Thrust block design for AB-DF Ductile Iron Fitting (Anchor Block)
5.7.2.1 Purpose
The main purpose of thrust block is to prevent AB-DF fittings in the pipe line from
moving when pressure load is applied. The thrust blocks absorb the load from the
AB-DF fitting and transfer it to a wide load bearing area on the wall of trench. Thrust
blocks are required whenever pipelines;
z Change its direction
z Reduce its diameter
z Ends
z Connected to Valve
z Negotiate a curve where a soft soil condition is encountered.
5.7.2.2 Installation
It is very good practice to ensure that the pipe adjacent to the AB-DF fittings are firmly
secured before installation of thrust blocks. For buried pipe application, fittings are
usually restrained by concrete blocks cast at site. This is to ensure that neither the
AB-DF fittings nor the AB-3P/Other connected pipes will move when thrust block has
been installed. The thrust block should be positioned symmetrically along the line
through which the resultant thrust acts and rest firmly against the side of trench.
The soil type and depth will also affect the efficiency of the thrust transfer but to make
easier reference, here is some indicative thrust block size.
5.7.2.3 Typical Thrust Block
Sufficient support should be provided at AB-DF joint to ensure that the joints do not
move when subjected to internal hydrostatic pressure. You may find guideline
standard thrust block dimension in Appendix 4. However the dimension varies when
soil condition is changed like soft soil or hard rock. Please consult with professional
consultant.
Figure: Thrust Block

1. Gate valve using paddle flange 2. AB-DF Tapered Reducer
3.&4. AB-DF 45 deg Bends 5. AB-DF Blank Ends 6. AB-DF Equal Tee
5.8 Solvent Cement Jointing
For light application in the building etc, solvent cement jointing with PVC fittings can be also
used. To achieve a strong joints in a pressure pipe works, the correct type of solvent cement
must be used. ME-Plas(M) strongly recommends Mighty® solvent cement which is
manufactured with a controlled amount of resin
and solvents.
It must be emphasized that this is not a gluing
process, instead an adhesion mechanism
achieved through the molecular bonding of resin
solidification as the solvents evaporate which is
very similar like welding.
However, it shall be strongly emphasized that
due to the dependency of workmanship which is
usually beyond control of end client, we strongly
recommend to use Bell mouth Rubber Ring joint
and AB-DF Fittings unless it is impossible to
avoid Solvent Cement Joint. “Supa-Tite” Rubber Ring Joint method is much more reliable than
any Solvent cement or Fusion welding or even HI-3R:ABS injection molded fitting joint.
Also note that for bigger diameter pipe, the complete application of solvent cement also takes
some time. If you use quick drying type, you can not achieve proper connection. So there are
two types of solvent cement you may choose.
z Recommended for jointing pipes of 15-80 mm diameters.: Mighty Extra No 70
z Recommended for jointing pipes of 80-200 mm diameters: Mighty Extra No 10
We also recommend using blue or green colored solvent cement even if it is a little bit higher
cost. With colored solvent cement, worker can easily identify the even spreading and
application of solvent cement on the surface of pipe to be joined.
We can supply above solvent cement, 1 inch brush (For 100mm and above diameter) and clean
mope for primer application with more economical price than other retailed outlet.
If pipe is larger than 100mm, use 1 inch wide brush to apply solvent cement which is faster to
prevent curing before actual joint insertion. So choose proper brush and try to pull out brush
hairs with your finger and take out all loosened hair so that it will not be stuck on the pipe while
applying it. Loosened hairs of brush may cause leakage problem.
5.8.1 Above Ground Solvent weld jointing instructions
z Make a square cut using a mitre box and fine-toothed panel saw.
z Remove all burrs and swarf.
z Slightly chamfer the external pipe edge.
z Clean the pipe and matching socket, using priming fluid to the manufacturer's pipe
recommendations.
z Keep the cleaned surfaces free of dirt and grease. Failure to do so could lead to
inadequate bonding and will result in joint failure.
NOTE: This is a very important step: the priming fluid not

only cleanses the surface but also prepares for a durable
and long lasting joint.
z Draw a line on the spigot to show the depth of socket.
z Apply an even coating of approved solvent cement to the
inside of the socket and spigot, over an area
corresponding to the socket depth.
z While the surface is still wet, push the spigot home into the
socket with a slight twisting motion.
z Hold the cemented joints for 10 seconds without
movement.
z Clean the excess of solvent cement with a clean cloth.
z The pipe may be handled, but not unduly strained for1
hour.
z Wait 24 hours before testing or use.
5.8.2 Underground Buried Solvent Cement Jointing

In case of underground application, extreme care shall be
taken.
z Lay the pipe before making solvent welding.

z Follow the step of “5.7.1 Above ground jointing”
procedure.
z After jointing is done, immediately backfill the pipe trench.
This will reduce any excessive expansion or contraction during the curing process
of solvent weld joint.
z This joint will sustain the end thrust to which the pipe will be submitted when under
pressure. Care should be taken that excess adhesive does not flow into the pipe
bore.
z Wipe off any that has been expelled from the mouth of the bell mouth socket.
z Do not disturb the joint for at least 30 minutes although the jointing may continue.
It shall be noted that ME-Plas(M) VERY STRONGLY INSIST to use “Supa-tite”
rubber ring joint and AB-DF fitting solution unless solvent cement joint is
completely unavoidable.
5.9 Expansion and Contraction

Distortion can occur when laying pipes in direct sunlight. When one side of the pipe is hotter
than the other, it may develop a bent shape which may make jointing difficult.
However, this used to happen in polymer pipe such as PE, ABS or bad quality uPVC but AB-3P
has much less heat expansion rate than above. However, in any case if this happens, plastic
pipe will contract as it cools, after laying in hot weather. A 6 meter length of AB-3P will expand
or contract approximately 3~4mm for each 10°C rise or fall in temperature. In PE pipe case, it
will be 9mm, in case of ABS pipe, it will be 7 mm. So backfill each length, at least partially, as
laying proceeds to ensure that the heat expansion will not be so much. Refer Section 4.3.2 and
4.3.3. Rubber rings allow some movement of the pipeline during and after completion of the
laying operation to ensure that the joints do not slipped out. In fact, AB-3P’s unique rubber ring
design ensure water tightness than any other rubber ring design to ensure joint against
thermal changes. Therefore, even with freezing winter time and hot summer time, this joint
allows better performance for heat expansion and contraction as well as external and internal
vibration movement such as water hammering, earthquake.
5.10 Curved Installation

AB-3P unique “Supa-tite” Rubber ring joint of AB-3P pipe allows around 5° of angular deflection
without AB-DF fittings. Nonetheless, Joints should always be made with the two pipes straight.
Deflection should be made only after the joint is made. Also AB-3P pipe itself is flexible at
certain degree thus minor changes in direction can be achieved by jointing and then deflecting
a subsequent pipe. Also above figure considered additional marginal safety factor as well.
AB-3P Pipes of smaller sizes are flexible enough to be easily deflected. The route of pipe should
be curved evenly along its length so that strain is not taken by the joint. The pipes should
always be joined directly in line before the curve is made. Radius of bending should not exceed
200 times the diameter of pipe. In principle, Local Water Authorities should be consulted on
whether or not curved AB-3P pipes are allowed to be drilled or fitted with tapping bands.
5.11 Concrete Encasement

AB-3P pipes may be encased in concrete. Where the concrete face cannot be located on a
socket, compressible material approximately 3mm thick and for a distance of about 100mm
from the face into the concrete should be used around pipes. By encircling the pipes at the
entry and exit points, any potential sharp edges will be prevented from bearing against the pipe
wall. The pipeline should not be pressurized with water until the concrete has developed
sufficient strength to resist tensile stresses. This could be used for highway road crossing
instead of sleeve. For main highway, we recommend to use one size bigger pipe for sleeve
rather than concrete encasing to consider any possible maintenance in the future.
5.12 Backfilling
Mechanical joints, especially flanged joints of AB-DF and its ancillary devices, should be left
exposed if possible until the line is tested.
Pipes should be covered where there is a possibility of the trench filling with water due to rain,
etc. as flotation of the empty pipeline will occur unless it is backfilled to a height of at least one
and a half diameters above the pipe.
Before backfilling, pump any accumulated water from the trench.
Do not tip fill directly from dump truck into trench.
The method of placing the remainder of the trench backfill will depend on whether the pipeline
is located in an area with no traffic loading or under a roadway.
In a roadway it is normal practice to continue backfilling and compacting with good quality
embedment material up to pavement level. Heavy compaction of backfill should not commence
without at least 300mm of material covering the pipeline.
When assembly of pipe line is suspended, do not leave tools, cement, lubricants etc in the
trench or inside of piping. Also cover the open end of pipe line with proper Endcap supplied
with AB-3P pipe. It has small hole in the center thus can also breath and protect from mud and
debris to ingress into the pipe.
5.13 Pressurized and Non-pressurized Tapping

Before tapping, please contact local authority for permit. Check you have all proper equipment
to make tapping to polymer pipe. There are two types of tools for AB-3P pipe. It is exactly same
for PE or uPVC or ABS.
AB-3P also can tapping directly if it is not pressurized. However, this practice does not give
good result due to the bad workmanship mostly. Also contractor seldom have appropriate tools
and follow procedure stringently. So we strongly recommend to use tapping saddle for
applicable case. We also supply pressurized ductile iron tapping saddle as a part of AB-DF
system. We do not recommend using Cast iron Saddle since it is quite brittle and showed many
failures.
However, make sure to use saddles specially designed for polymer pipe. AB-DF saddle is
specially designed and in fact, has stronger gripping onto slippery polymer pipe surface with
latest design. You can see that internal rubber pad design is different with other saddle.
It shall have screwed groove inside of cutter to hold drilled pipe wall or another type is at the
tip of drill which is on the center of cutter, they have cut-pipe wall holding pin. See photos
below.
Screwed cutter type Holding Pin type Ductile Iron Tapping

Saddle with Convex Liner Grip
Precaution:
Please do not use PE tapping saddle which does not has internal rubber ring to fight against slip
on the pipe surface. Without internal rubber, tapping may turn or even slipped along pipe
length.
General Tapping Procedure
z Mount the saddle
Fit the ferrule/strap on to the saddle. Fasten the saddle with bolt and nuts.
Place the flat washer over the ferrule stem.
Screw Tapping device on to the stem and open the valve in the body
Make sure the cock built in the ferrule is correctly open and all screws are tightened
before setting drill.
z Drilling
Rotate T or X bar to advance spindle until the cutter touch pipe wall
When it touches, slow down the feed.
Give additional feed to pierces the pipe wall. (1 cm or depending on pipe size)
Withdraw the spindle/cutter fully and close the valve.
Unscrew the complete head-works from the valve body
z Completion
After raising the drill, close the ferrule.
Make sure that your cutter hold cut pipe piece so that it will not go in the pipe and
stuck to water meter.
5.14 Connection to Water Meter and Stand pipes and vertical riser
For meter installation above the ground, the AB-3P Pipe should be terminated approximately 1
meter before vertical riser which is normally GI or Stainless steel pipe. However, you may also
use AB-3P for the vertical riser but in such a case, you shall support properly so that it will not
be easily damaged by the pedestrian abuser as well as holding firmly when internal hydro
stress may not move the riser. It is also wise to design it away from pedestrian walkway since
exposed vertical riser usually abused by malicious pedestrian or vehicle accident which any
kind of small size pipe can not tolerate the shock.
5.15 Prevention from Floating

Adequate measures shall be made to prevent floatation of pipe due to the ground water or
similar before backfilling is completed. However, unlike PE, AB-3P pipe material is heavier than
water thus you may partially backfill the pipe main body, not the joint or fitting, than it will not
float anymore.
5.16 Pre-Assembly and laying

Unless trench has a lot of existing communication pipes for electricity, water, gas etc, you can
pre-assemble bell-mouth rubber ring joint on the ground to make your connection easier if you
want. But, when you push pipes into the trench, make sure that there is no sharp material like
stone or nail which may damage AB-3P pipe.
However, AB-DF shall be joined in the trench. After push pre-assembled pipe in the trench,
make sure that rubber ring joint inspection line is still in position and does not comes out
beyond tolerance which is 5 mm.
5.17 Site Testing

The site testing requirements should be carried out according to the local Water Authorities. It
is recommended that the test is carried out at the pressure of 1.5 times the lowest rated
component of the pipeline.
Sample Procedure:
1. Pressure test as short a length of pipeline as possible.
2. Ensure that all air release valves are working properly. We found AVK® air valve is reliable
and many of other local brands do not show reliable and consistent result as of 2006.
3. Open filling valve very slowly and only about 10% of capacity to ensure gradual filling.
4. Allow pipeline to fill and pressurize to working pressure.
5. Allow two hours for pipeline to settle under pressure.
6. Pressurize as necessary back to working pressure as air slowly escaping out of water will
show a reduction of pressure.
7. Once satisfied that no leakage have monitored, then increase pressure gradually until test
pressure of 1.5 times working pressure. E.g. if working pressure is 7 bar maximum, then
increase to 10.5 bar, if 12 bar increase to 18 bar.
8. Maintain test pressure for 1 hour only.
9. When installing T such as scour and hydrant tees, it is important that the leg of tee is
blanked off then pressure tested to allow pipe movement to take place.
10. Once pressure test has been completed, the necessary thrust block must be installed.
The test usually performed for more than one hour. Water in the pipeline may require
replenishment depending on the pipe wall temperature due to expansion.
Solvent cement joints should be allowed to cure for at least 24 hours from the time of the last
joint made. All concrete works should be fully cured before carrying out pressure test.
It shall be noted that proper procedure shall be followed. Specially, make sure that air valve is
working properly and also fill in the water from lower part to upper part so that no air will be
trapped in the middle. ME-Plas(M) Sdn Bhd has sample guideline site testing procedure and it
is available on request. It shall be also note that do not pressure pipeline to 1.5 times more
than once as it will reduce the life time span of AB-3P pipe. Since usual application of normal
working pressure of pipe is less than nominal pressure rating, AB-3P pipe and AB-DF can be
used even longer than 50 years unless severe cyclic stress is continuously imposed.
6 Repairing
When AB-3P is damaged, you can easily repair it using short length of AB-3P pipe together with
two AB-DF Straight Couplings. However, you need to push in and out to give space on both side
of repair pipe. Therefore, when you order AB-DF Couplings for Repair, please advise them to
take off the Pipe stopping notch in the center of Coupling. Alternatively, you may also knock it
off by yourself but make sure that Cold Epoxy Touch-up Painting is very important afterward to
protect exposed metal part. See drawing attached. You may also use repairing kit to patch
minor punched part.
7 Training Program
ME-Plas(M) Sdn Bhd provides very effective Contractor training program either at factory in
Nilai, Malaysia or at the Site at Malaysia.
We demonstrate how to connect pipe and also how they can perform construction works
effectively. Also we demonstrate using proper tapping equipment.
To avoid any clogging of the meter or branch pipe, Contractor shall use proper Polymer tapping
tool. In case contractor is too small to purchase the tools, please contact our distributor in each
region and they will offer very economical and attractive proposal to perform the works
professionally.
Please request ME-Plas(M) or AB-3P distributor “AB-3P & AB-DF Installation Quick Reference”
leaflets to distribute to your contractor so that they will know easily how to install pipe and
fitting. We highlight that AB-3P and AB-DF is very easy to install but for flange joint to connect
to other valve S-bend etc, please pay your attention and supervise thus let them follow
stringently the procedure.
8 Pre-Sales Service (PSS) & After Sales Service (ASS)
ME-Plas(M) is the only company who provides you patented latest proven system solution and
technology for its material as well as project management and site quality control.
We are the only manufacturer who also has a qualified Project Management Professional
certified by PMI USA as well as 20 years or more infrastructure construction project expert to
assist end client, particularly water network operator. So engage us from project initial design
stage until the life time of the project. We will be always besides you to assist.
In any time, you can contact our distributor and request for technical service whatsoever
problem you are facing during the site works. We do not blame the contractor for bad works
after works is done but rather establish good partnership and assist and cooperate with them
to achieve the best quality water network system for end client. So send us e-mail address then
we will send all training data for the education of contractor.
-- AB-3P and AB-DF ULTIMATE SYSTEM SOLUTION FOR WATER PIPE NETWORK --
Appendix 1. General Properties of AB-3P
Item Unit Typical Value
General Properties
Specific Gravity 1.38
Self extinguishing
Flammability
Not support combustion
Heat Reversion Less than 5%
Maximum continuous serviceable °C 60
temperature
Thermal Properties
Thermal conductivity w/m/*C 0.14
Specific Heat kj/g/*C 1.05
Coefficient of linear expansion Per *C 5 x 10
Vicat softening Temperature °C 80
Welding Temperature °C 180 ~ 185
mm/m/degree 0.07
Coefficient of thermal expansion
rise
Electrical Properties
Breakdown voltage k-volt 35 min on 1.8 mm
Volume Resistivity Ohm cm* 10
Dielectric Constant @106Hz - 3.5
Dielectric Strength kV/mm > 40
Dielectric Power Factor @106Hz - 0.02
Mechanical Properties
Modulus elasticity Gpa ~ 3.3
Hardness Rockwell R 120
Water Absorption mg/cm2 0.04 – 0.06
Tensile Strength MPa > 51
Elongation at Break % > 80
Compressive Strength MPa 66
Modulus of Elasticity MPa 2700
Izod Impact Strength kJ/m2 >9
Appendix 2. AB-3P Internal Diameter, Out-Diameter, Thickness Quick
Reference Table
AB-3P PN 9+ PN 12+ PN 15+

Norminal OD t ID t ID t ID
(mm) AVR Average AVR Average AVR Average AVR
15 21.4 Non-MS Non-MS Non-MS Non-MS 1.9 17.6
32 42.3 Non-MS Non-MS 2.5 37.4 3.0 36.4
40 48.3 Non-MS Non-MS 2.8 42.8 3.4 41.5
50 60.4 2.8 54.9 3.4 53.6 4.2 52.0
65 75.2 3.3 68.7 4.2 66.8 5.2 64.9
80 88.9 3.8 81.3 5.0 79.0 6.2 76.6
100 114.3 4.9 104.6 6.5 101.4 7.9 98.6
125 140.2 6.0 128.3 7.9 124.5 9.7 120.8
155 168.3 7.1 154.1 9.5 149.3 11.7 145.0
200 219.1 8.4 202.3 11.1 196.9 13.6 192.0
250 273.0 10.5 252.1 13.8 245.4 16.9 239.2
300 323.9 12.4 299.1 16.4 291.2 20.2 283.6
350 355.5 13.6 328.4 18.0 319.6 22.1 311.4
400 406.4 15.6 375.2 20.5 365.5 25.2 356.0
Appendix 3. AB-3P Chemical Resistance Chart
(O) Resistant and suitable (X) Not resistant so not-suitable
Chemical Concentration 20 Deg C 60 Deg C
Acetaldehyde 40% aqueous solution O X
100% X X
Acetic Acid 10% aqueous solution O O
60% aqueous solution O O
Glacial X X
Acetic anhydride X X
Acetone Traces X X
100% X X
Acetonitrile X X
Acetophenone X X
Adipic acid O ?
Aktivin (Chloramine) 1% aqueous O O
Alcohol. allyl ? X
Alcohol. amyl O O
Alcohol benzyl X X
Alcohol. butyl O ?
Alcohol. ethyl 40% w/w in water O ?
100% O ?
Alcohol. furturyl X X
Alcohol. hexyl O O
Alcohol. isopropyl O O
Alcohol. methyl 6% aqueous O O
100% O ?
Alcohol. nonyl O O
Alcohol. octyl O O
Alcohol. propargyl O O
Allyl chloride X X
Aliphatic hydrocarbons O O
Alum Saturated aqueous solution O O
Aluminium acetate Saturated aqueous solution O O
Aluminium fluoride Saturated aqueous solution O O
Aluminium hydroxide Saturated aqueous solution O O
Aluminium nitrate Saturated aqueous solution O O
Aluminium oxalate Saturated aqueous solution O O
Aluminium oxychloride O O
Aluminium potassium sulphate Saturated aqueous solution O O
Aluminium sulphate Saturated aqueous solution O O
Amber acid aqueous O O
Ammonia Dry gas O O
Liquid X X
Ammonium bicarbonate Saturated aqueous solution O O
Ammonium bifluoride Saturated aqueous solution O O
Ammonium carbonate Saturated aqueous solution O O
Ammonium chloride Saturated aqueous solution O O
Ammonium flupride Saturated aqueous solution O O
Ammonium hydroxide 0.88 S.G. aqueous solution O O
Ammonium metaphosphate Saturated aqueous solution O O
Ammonium nitrate Saturated aqueous solution O O
Ammonium oxalate Saturated aqueous solution O O
Ammonium persilphate Saturated aqueous solution O O
Ammonium phosphate Saturated aqueous solution O O
Ammonium sulphate Saturated aqueous solution O O
Ammonium sulphide Saturated aqueous solution O O
Ammonium thiocyanate Saturated aqueous solution O O
Amyl acetate X X
Amyl chloride X X
Aniline X X
Aniline hydrochloride X X
Aniline sulphate X X
Anisole X X
Anon See cyclohexane
Anthraquinone X X
Anthraquinone sulphonic acid O O
Antimony chloride O O
Antimony Trichloride O O
Apple acid Aqueous O O
Aqua regia O X
Arsenic acid Concentrated ? ?
Arylsulphonic acids X X
Barium chloride Saturated aqueous solution O O
Barium hydroxide Saturated aqueous solution O O
Barium sulphide O O
Beff tallow emulsion Usual commercial O O
sulphonated
Beer O O
Beeswas O O
Barium sulphide O O
Benzaldehyde Traces X X
100% X X
Benzene X X
Benzoic acid Saturated aqueous solution ? X
Benzoyl chloride X X
Benzyl acetate X X
Benzyl alcohol X X
Bisulphite See sodium bisulphite
Bismuth carbonate O O
Bleaching lye O O
Bone tallow X X
Borax Saturated aqueous solution O ?
Boric acid Saturated aqueous solution O ?
Boron trifluoride O
Brandies all types Usual commercial O O
Brine O O
Bromine Traces, gas ? X
100% (dry gas) X X
Liquid X X
Butadiene O O
Butane O O
Butanediol Aqueous up to 10% O ?
Butanol Up to 100% X ?
Butoxyle O
Butyl acetate X X
Butyl chloride X X
Butylraidehyde X X
Butyric acid 20% aqueous solution O O
Concentrated X X
Calcium chlorate aqueous solution O O
Calcium chloride aqueous solution O O
20% in methyl alcohol O O
Calcium hydroxide aqueous solution O O
Calcium nitrate aqueous solution O O
Calcium phosphate Saturated aqueous solution
Camphor oil O O
Carbon dioxide O O
Carbon disulphide X X
Carbon acid O O
Carbon monoxide O O
Carbon tetrarchloride X X
Castor oil O O
Caustic potash lye up to 40% O O
Chloracetic acid 60% aqueous solution O ?
Chloric acid 20% aqueous solution O O
Chlorine Dry gas (traces) O O
10% (moist gas) ? X
Chlorine trifluoride X X
Chlorine water Saturated solution ? X
Chlorobenzene X X
Chloroform X X
Chlorsulphonic acid Technically pure ?
Chrome alum Saturated aqueous solution O O
Chromic acid 50% aqueous solution O O
Cider O O
Citric acid Saturated aqueous solution O O
Clophenes usual commercial O O
Coal gas benzene free O O
Coconut tat alcohol technically pure O O
Copper chloride Saturated aqueous solution O O
Copper fluoride Saturated aqueous solution O O
Copper nitrate Saturated aqueous solution O O
Copper sulphate Saturated aqueous solution O O
Cuprous chloride saturated O O
Corn oil O O
Creosote X X
Cresols X X
Crotonaldehyde X X
Cumene technically pure ? ?
Cyanide of potash ₩ ? Tot 10%
Cyclohexanol X X
Cyclohexanone X X
Decahydronaphthalene technically pure O O
Densodrin W Usual commercial O O
Dextrin Saturated aqueous solution O O
Dextrose Saturated aqueous solution O O
Diamyl ether X X
Dibutyl phthalate X X
Dichlorodifluoromethane O
Dichlorethylene X X
Dichlorobenzene X X
Diesel oil O ?
Diethylene glycol O O
Diethyl ether X X
Diethyl ketone X X
Diglycolic acid 30% O ?
Dimethylamine X X
Dinonyl phthalate technically pure X X
Dioctyl phthalate X X
Dioxane X X
Disodium phosphate Saturated aqueous solution O O
Ethane O O
Ether X X
Ethyl acetate X X
Ethyl acrylate X X
Ethyl butyrate X X
Ethyl chloride X X
Ethyl formate X X
Ethyl lactate X X
Ethyl sulphate O ?
Ethylene bromide X X
Ethylene chlorhydrin X X
Ethylene chloride X X
Ethylene dibromide X X
Ethylene dichloride X X
Ethylene glycol O O
Ethylene oxide X X
Ferric chloride Saturated aqueous solution O O
Ferric nitrate Saturated aqueous solution O O
Ferric sulphate Saturated aqueous solution O O
Ferrous ammonium citrate Saturated aqueous solution O O
Ferrous chloride Saturated aqueous solution O O
Ferrous sulphate Saturated aqueous solution O O
Ferrous sulphate Saturated aqueous solution O O
Film developer Usual commercial O O
Flourine X X
Flousilicic acid O O
Formic acid 50% aqueous solution O ?
Frigen, 12 (Freon 12) 100% O
Fructose O O
Fruit pulp O O
Fuel oil O O
Furfural X X
Furfuryl alcohol X X
Gelatine aqueous all O O
Glucose Saturated aqueous solution O O
Glycerol O O
Glycerol monobenzyl ether X X
Glycolic acid O O
Grape sugar Saturated aqueous solution O O
Heptane O O
Heptane O O
Hexane O O
Hollander glue Working concentration O O
Hydrobromic acid 50% aqueous solution O O
Hydrochloric acid 10% aqueous solution O O
concentrated O O
Hydrocyanic acid O ?
Hydrofluoric acid 4% aqueous solution O ?
40% aqueous solution O ?
60% ? X
concentrated X X
Hydrogen O O
Hydrogen bromide anhydrous O O
Hydrogen flouride anhydrous O O
Hydrogen peroxide 4% (10 volume) O O
12% (40 volume) O O
30% (100 volume) O O
90% and above O O
Hydrogen phosphide O O
Hydrogen sulphide O O
Hydroquinone Saturated aqueous solution O O
Hydroxylamine sulphate Saturated aqueous solution O O
Hypochiorous acid ? X
Iodine Solution in potassium iodide X X
Isophorone X X
Jam Usual commercial O ?
Lactic acid 10% aqueous solution O O
100% X X
Lanoline O O
Lauric acid O O
Lauric acid O O
Lead acetate Saturated aqueous solution O O
Lead nitrate Saturated aqueous solution O O
Lead tetraethyl O O
Linoleic acid O O
Liseed oil O O
Magnesium chloride Saturated aqueous solution O O
Magnesium nitrate Saturated aqueous solution O O
Magnesium sulphate Saturated aqueous solution O O
Maleic acid 25% aqueous solution O ?
concentrated O ?
Malic acid Saturated aqueous solution O O
Manganese sulphate Saturated aqueous solution O O
Menthol ? X
Mercuric chloride X X
Mercuric cyanide Saturated aqueous solution O O
Mercurous nitrate Saturated aqueous solution O O
Mercury O O
Mersol D O O
Mesityl oxide X X
Methyl acetate X X
Methyl bromide X X
Methyl chloride X X
Methyl cyclohexanone X X
Methyl ethyl ketone X X
Methyl isobutyl ketone X X
Methyl methacrylate X X
Methyl sulphate O ?
Methy sulphuric acid 50% aqueous solution O O
Methylene chloride X X
Milk O ?
Mineral oils Without additives O O
Mixed acids Sulphuric acid/nitric acid/water O ?
Molasses O O
Monochlorbenzene X X
Morpholin X X
Naphtha X X
Naphthalene X X
Nekal BX Diluted O ?
Nickel chloride Saturated aqueous solution O O
Nickel nitrate Saturated aqueous solution O O
Nickel sulphate Saturated aqueous solution O O
Nicotine Saturated aqueous solution O O
Nicotinic acid Saturated aqueous solution O O
Nictric acid 5% aqueous solution O ?
70% aqueous solution ? ?
95% aqueous solution X X
Nitrobenzene X X
Nitropropane X X
Nitrous fumes moist ? X
Octane O O
Octyl cresol Technically pure X X
Oleic acid O O
Oleum 10% X X
Oxalic acid Saturated aqueous solution O O
Oxygen O O
Ozone O X
Paraffin oil O O
Pentane O
Perchloric acid X X
Petrol/Benzene mixture 80:20 ratio X X
Phenol Saturated aqueous solution O ?
Phenylhydrazine X X
Phenylhydrazine hydrochloride ? X
Phosgene gas O
Phosphoric acid 20% aqueous solution O O
Phosphorus pentoxide Decomposed water O O
Phosphorous trichloride X X
Phthalic anhydride Solution in ethyl alcohol O O
Picric acid 1% w/w in water O O
10% w/w in alcohol O O
Potassium acid sulphate Saturated aqueous solution O O
Potassium bicarbonate Saturated aqueous solution O O
Potassium bisulphate Saturated aqueous solution O O
Potassium borate Saturated aqueous solution O O
Potassium bromate Saturated aqueous solution O O
Potassium bromide Saturated aqueous solution O O
Potassium carbonate Saturated aqueous solution O O
Potassium chlorate Saturated aqueous solution O O
Potassium chloride Saturated aqueous solution O O
Potassium chromate Saturated aqueous solution O O
Potassium cuprocyanide Saturated aqueous solution O O
Potassium cyanide Saturated aqueous solution O O
Potassium dichromate Saturated aqueous solution O O
Potassium terricyanide Saturated aqueous solution O O
Potassium terrocyanide Saturated aqueous solution O O
Potassium hydroxide 1% aqueous solution O O
Potassium hypochlorite 10% aqueous solution O O
Potassium nitrate concentrated O O
Potassium perborate Saturated aqueous solution O O
Potassium permanganate Saturated aqueous solution O O
Potassium persulphate Saturated aqueous solution O O
Potassium phosphate Saturated aqueous solution O O
Potassium sulphate Saturated aqueous solution O O
Potassium sulphide Saturated aqueous solution O O
Potassium thiosulphate Saturated aqueous solution O O
Propane O
Propylene dichloride X X
Propylene glycol O O
Propylene oxide X X
Saccharose Saturated aqueous solution O O
Salicylic acid Saturated aqueous solution O O
Sea water O O
Selenic acid X X
Silicic acid, aqueous All O O
Silicone oil Technically pure X X
Silver acetate Saturated aqueous solution O O
Silver nitrate Saturated aqueous solution O O
Silver salts aqueous diluted O ?
Smelting, gases, dry Saturated aqueous solution O O
Soda Saturated aqueous solution O O
Sodium acetate Saturated aqueous solution O O
Sodium acid sulphate Saturated aqueous solution O O
Sodium aluminate Saturated aqueous solution O O
Sodium antimonate Saturated aqueous solution O O
Sodium benzoate Saturated aqueous solution O O
Sodium bicarbonate Saturated aqueous solution O O
Sodium bisulphate Saturated aqueous solution O O
Sodium bisulphite Saturated aqueous solution O O
Sodium carbonate Saturated aqueous solution O O
Sodium chlorate Saturated aqueous solution O O
Sodium chloride Saturated aqueous solution O O
Sodium chlorite aqueous diluted O ?
Sodium cyanide Saturated aqueous solution O O
Sodium terricyanide Saturated aqueous solution O O
Sodium terrocyanide Saturated aqueous solution O O
Sodium fluoride Saturated aqueous solution O O
Sodium hydroxide 1% aqueous solution O O
Sodium bicarbonate 10% aqueous solution O O
concentrated O O
Sodium hypochlorite 15% CL O O
Sodium hypochlorite aqueous diluted O O
Sodium hyposulphate Saturated aqueous solution O O
Sodium metaphosphate Saturated aqueous solution O O
Sodium nitrate Saturated aqueous solution O O
Sodium nitrite Saturated aqueous solution O O
Sodium perborate Saturated aqueous solution O O
Sodium phosphate Saturated aqueous solution O O
Sodium pyroborte Saturated aqueous solution O O
Sodium silicate Saturated aqueous solution O O
Sodium sulphate Saturated aqueous solution O O
Sodium sulphide 25% aqueous solution O O
concentrated O O
Sodium sulphite Saturated aqueous solution O O
Sodium thiosulphate Saturated aqueous solution O O
Soft soap Saturated aqueous solution O O
Spermaceti Usual commercial X X
Sperm-oil-alcohol Usual commercial O O
Spindle oil O O
Spinning bath acids cont CSz 100mg/1 O O
Starch soluble Saturated aqueous solution O O
Starch syrup O O
Steariic acid Saturated aqueous solution O O
Sucrose Saturated aqueous solution O O
Sugar syrup O ?
Sulphur colloidal O O
Sulphur dioxide dry O O
Moist O ?
Liquid ? X
Sulphuric acid 10% aqueous solution O O
Sulphuric acid 50% aqueous solution O O
fuming X X
Sulphurous acid 10% aqueous solution O O
Tallow Technically pure O O
Tannic acid Saturated aqueous solution O O
Tartaric acid Saturated aqueous solution O O
Test benzine O O
Tetraethyl lead O O
Tetrahydrofuran X X
Tetrahydronaphthalene X X
Thionyl chloride X X
Tin (II) chloride, aqueous aqueous O ?
Toluene X X
Transformer oil Non-aromatic O O
Tributyl phosphate X X
Trichloroacetic acid O X
Trichlorethylene X X
Trichlorobenzene X X
Tricresyl phosphate X X
Triethylene glycol O O
Trimethylpropane O ?
Trioctyl phosphate X X
Turpentine O O
Urea O O
Urine O O
Vaseline X X
Vegetable Oils O O
Vinegar O O
Vinyl acetate X X
Water O O
Wax alcohol O O
Wines and spirits O O
Xylene X X
Zinc chloride O O
Appendix 4. Sample Thrust Block dimension guideline
z Determination of forces on fittings
The thrust in the direction of each leg is given by:
Fy = ρA
Where A = Cross sectional Area of pipe (mm)
ρ = Internal pressure (N/mm2)
Fx = ρA Cos α α = Angle of deviation of the pipe (degree)
F = thrust in Newton
The resultant outward thrust is the vector sum of the forces in both direction of the pipe
axis and is given by;
FR = 2 ρA sin α/2
AB-DF 45 deg Bend

(2G type)
For T branch and end cap, the

resultant outward thrust is given
by
FR = ρA AB-DF Endcap
ÆFR
AB-DF T-Branch
(2G1F Type)
Reducer, the thrust force is given

by:-
FR = ρ(A1 – A2) = ρ π/4 (d12 – d22)
Where d1=Big pipe side Internal
diameter, d2=Small pipe side ID
Figure: Thrust force based on Internal pressure of 10 bar
Right figure shows the

approximate thrust force acting
on fittings with an internal
pressure of 10 bar.
For internal pressure of 6 bar,
the resultant thrust force can be
calculated by multiplying the
values obtained from figure by a
factor of 0.6.
z SAFE BEARING LOAD

We must ensure that the soil around the trenches where the pipeline is being laid is
capable of absorbing the load induced by the internal water pressure. Typical safe
bearing load values for soil in trenches where the soil cover over the pipe is 450mm or
more are given in the table below.
Table: Safe bearing load for different soil.
Material Safe Bearing Load
(kN/m2)
Peat, running sand, muck, ash 0
etc.
Soft clay 50
Medium clay; Sandy loam
Sand & gravel 100
Hard clay 150
Sand & gravel cemented with clay 200
Rock 240
z DETERMINATION OF THRUST BLOCK SIZE
Example:
Calculate the bearing area of a thrust block for a 400mm (external diameter) pipe with
a 45° bend on a AB-3P main in very hard clay. The internal pressure is 10 bars.
From above figure, the outward thrust acting on the 45° bend is about 75.30 KN.
From above table, the safe bearing load of hard clay is 150 kN/m
Bearing area of thrust block required,
F/ Safe bearing load of soil = 75.30/150 = 0.502m2
Figure: Bearing area
Referring to the minimum support

needed for bends where Be > De (see
the following page), the recommended
length w should be at least 1 meter long
and the minimum depth d shall be 0.5m.
Therefore, we suggested bearing area
dimension = d x w = 0.5 x 1.0 = 0.5 m2.
z THRUST BLOCK DIMENSION

Sufficient support should be provided at all AB-DF fittings to ensure that the joints do
not move when subjected to internal hydrostatic pressure including water hammering.
Basically, the minimum dimension required is:
Horizontal Bend
Bends: Be > De (minimum 150mm)
Branches:
Be1 > De + de/2, (minimum 200mm +
de/2)
Be2 > de + De/2, (minimum 200mm +
De/2)
Convex
Vertical Bend Concave Vertical Bend
T-Branch Pipe-End
But at least,
Be1 = De + de/2 Be1 = 200mm + de/2 or
Be2 = de + De/2 Be2 = 200mm + De/2
To facilitate application for simple installation, please refer to attached drawing for
your due reference.
Please take note that this is only the guideline dimension varies when soil condition is changed like soft soil or hard
rock. Please consult with professional consultant. (Full size drawing available on request)
Appendix 5. Recommended Jointing Method Table
Notice
Copyright© 2004-2007 ME-Plas(M) Sdn Bhd and its licensors. All rights reserved. AB-3P, the AB-3P
& ME-Plas(M) logo, AB-DF logo are either registered trademarks or trademarks of ME-Plas(M) Sdn
Bhd in the Malaysia and/or other countries. HI-3P is registered trademarks of Gecom Korea. All
other trademarks are the property of their respective owners.
Limitation of Liability:
The information contained herein has been compiled only as quick reference assistance to qualified
contractors and engineers. This book should not be used as a sole source of information as it does
not refer to all aspects of pipeline design and installation. Further reference should be made to
established text books. So far as it may lawfully do so ME-Plas(M) Sdn Bhd of Malaysia supplies this
publication upon the basis and condition that it will incur no liability whatsoever in respect of any
loss or damage of any kind claimed to arise either directly or indirectly as a result of any statement
herein or in respect of any act cause matter or thing alleged to arise directly or indirectly as a result
of the contents of this publication and excludes all warranties and conditions statutory or otherwise
as to quality or fitness for any purpose and excludes all liability of itself, its servants and agents for
all loss or damage in relation to the use of the goods howsoever arising. Please note that overall
responsibility lies solely with the user to ensure the currency and validity of information or advice
contained herein in the context of his circumstances. It is recommended that advice be obtained
from a Registered Consultant. No warranty is expressed or implied as to the content of the
information or results obtained by use thereof, and ME-Plas(M) Sdn Bhd will not be held liable for
any costs, direct or indirect, that may arise there-from.

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AB-3P Technical Reference Manual

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THE NEXT MILLENIUM WATER PIPE SYSTEM

WWW.MEPLAS.COM.MY E-MAIL: MEPLAS@STREAMYX.COM

1.1 What is AB-3P? 5

1.2 How to make AB-3P? 5

1.3 No uPVC-phobia! Why? No backyard product. 5

1.4 Long time proven performance. 5

1.5 Certificate and Registration 5

1.6 System Solution 6

1.7 Superior Design 6

1.8 Color and marking 6

1.9 Real Lifetime, pipe for our descendant. 6

1.10 Super Fast Construction 6

1.11 Residual Chlorine and Bio-Film 6

2.1 Ambient temperature and Pipe pressure rating 7

2.2 Chemical resistance 8

2.3 Behavior in Fire 8

2.4 Abrasion Resistance 8

3 AB-3P/AB-DF PRODUCT FEATURES AND BENEFITS AB-3P PIPE 9

4.1 Hydraulic design 14

4.2 Structural Design 19

4.3 Above ground Installation 20

5.1 Transportation, Handling and Unloading 24

5.3 Fabrication, Cutting 25

5.4 Installation: Underground Trench Construction 26

5.5 Installation: Above Ground Exposed Construction 28

5.16 Pre-Assembly and laying 41

5.17 Site Testing 41

8 PRE-SALES SERVICE (PSS) & AFTER SALES SERVICE (ASS) 43

APPENDIX 2. AB-3P INTERNAL DIAMETER, OUT-DIAMETER, THICKNESS QUICK REFERENCE

APPENDIX 3. AB-3P CHEMICAL RESISTANCE CHART 46

APPENDIX 4. SAMPLE THRUST BLOCK DIMENSION GUIDELINE 60

APPENDIX 5. RECOMMENDED JOINTING METHOD TABLE 66

2.1 Ambient temperature and Pipe pressure rating

AB-3P is generally much stronger than BS or MS requirement thus depending on the

2.2 Chemical resistance

2.3 Behavior in Fire

2.4 Abrasion Resistance

3.1.2 Certification and Test Criteria

3.1.4 Anti-Bacteria, Safety Proven Nano-Technology

3.1.5 Pressure Pipes with Very Low flow friction

3.1.6 Residual Chlorine Absorption

3.2.2 Certification complied to BS/EN 545

3.2.3 AB-DF GLAND DESIGN – ADVANTAGES

3.2.4 AB-DF GLAND DESIGN – Exposed Application

The flow data of AB-3P can be obtained from the charts

V=-2 x SQRT(2gDS) . log(k/3.7D + 2.51√ /D x SQRT(2gDS) where;

V = mean velocity in m/s

4.1.3 Pipe INTERNAL Diameter Selection

4.1.4 Pressure class selection

4.1.5 Water hammer surges and cyclical effects

Table 3. Fatigue derating factors

Tees equal Dx3/4D Dx1/2D Dx1/4D

Reducers Dx3/4D Dx1/2D Dx1/4D

4.2 Structural Design

4.2.1 Minimum Cover Height

4.2.2 Thrust block for fittings

4.3 Above ground Installation

4.3.2 Heat Expansion & Contraction

∆TL = Maximum temperature change in pipe contents

If AB-3P is installed in the vibrating area or similar environment,

Table 5. Recommended Distance of Pipe Support

Pipes and fittings should not be dropped or thrown onto

5.3 Fabrication, Cutting

Cutting the pipe Square