Polypropylene Random (PP-R) MUS Le dro-Sanitary Applications——_____________——e (Cosmoplast) e—————_______ Cosmoplast, a primary member of Group Harwal, has been a the fretront ofthe plastic industry in the Gulf region since Pee Cet cee eee ee eee eae tes ies eee se eae g ey Continuously enhancing ts capabiltes in plastic manufacturing technologies, Cosmoplast now ullizes a dverse range Ce ee een TG ae ee eel an ee eee el ae ‘copolymer polypropylene (PP-R], CPVG and RTP. Cosmoplast’s ongoing research and development programs continue to add new products to is pipeline systems product range that now includes pre insulated pipes, reinforced thermoplastic pipes, specialized plumbing systems and ee ee ee ea ae a eng capable of manufacturing moulds, dies, machinery equipments and other specialized tooling requirements to mest the ‘company’s continual expansion and product development requirements. With this extended product range, Cosmoplas’s pipaline systems cater to an extensive range of market sectors and applications covering inrastucture development, plumbing, ol & gas, district cooing, irigation, landscaping and water erry Does ee ea eee en eee ce eee Cen cared Geen ee aOR ees eC ge een) coer) eel TW Saag ey PRODUCT RANGE INCLUDES: RO Man sae tye PVC and Polyethylene pipeline systems with sizes ranging from 15mm up to 1200mm, Re ee eee ene oan ee eC ug pees SR ee ee cy PLUMBING SYSTEMS (UPVC, PP-R, PEX) Comprehensive range inclides uPVC & HOPE systems for drainage, CPVC, random potyoropylene (PP-A [olan fiberand Sen een ae on a ee nae ea eae Se et ee ee eee ee ed ore ee ae ecu cee PRE-INSULATED PIPES (HDPE-HOPE, HDPE-GRP, HDPE-STEEL, GRP-HDPE, GRP-GRP, GRP-STEEL) ‘Jacket — core pipe combination with polyurethane insulation ae used for applications such as District Goolng systems, OF ee ees tee ea ae ee aca ec eee IRRIGATION SYSTEMS (LLDPE) ‘Consists of high precision inline drip pipes and landscape and lawn edging, Ths range also includes saline resistant valves, Cee eae ice eee es Det Rea) ‘Avalable in length of upto 500m, with @ working pressure of 150 Bar at a temperature of 60 degrees celsius. RTP is used eet ee Lee he ow DvGw WRASCONTENTS Fields of Application 2 Features of Cosmoplast Polypropylene System 3 ‘Mechanical & Thermal Properties of PPR 4 Pressure and Temperature 5 Regression Curve of PPR 6 Pipes Specifications PN20 Plain PPR Pipes 7 PN16 Plain PPR Pipes 7 PN25 PPR / AL / PPR Stabi Pipes 8 PN25 PPR / AL / PE UV Resistant Pipes 8 PN20 PPR / FG / PPR Faser Pipes 9 PN25 PPR FG PPR Faser Pipe 9 PN 20 PPR FG PPR UV Resistant Pipe ee 9 Longitudinal Expansion 10 Pipe Supports 13 Pressure Loss ——__. 14 Pressure Loss Table for Pipes PN20 & PN25 at 20°C 15 Composite Polypropylene Pipes 16 Effective Clamping Distances ——__. 18 Expansion of PPR Composite Pipes ee 18 Fusion Welding Process 19 Welding Composite PPR / AL / PPR Stabi and PPR / Al / PE / UV Resistant pipes ee 20 Electro-fusion Welding Process 21 Handling, Storage and Transportation 22 Transport & Handling ——__. 23 Product Range ee 24 PPR Pipes 25 PPR Fittings 26 Piping System for Hydro-Sanitary ApplicationsCosmop ast POLyPropyLenE Pires & FITTINGS With the expertise of manufacturing thermoplastic pipeline systems in the Gulf region for more than two decades Cosmoplast has now developed 0 complete range of Polypropylene {PP-R} pipes and fitings for cold and hot water distribution systems. These pipes ond fitings ore suitable for potable woler distribution systems in addition to a wide range of hydro- sonitary applications. ‘The exceptional heat stability of the polypropylene Random copolymer and its extraction resistance coupled of installation make the PP-R system from Cosmoplasto reliable piping system fo thease 'ot and cold water applications with a service life in excess of 50 yeors. Cosmoplas! polypropylene system is made from PF-R gronules supplied by the world’s renowned resin manufacturers. These granules are pre-coloured and have excellent heat resistance, physical and chemical properties to suit ‘opplications such as potable woter distribution and heating systems. Fields of Application: The Polypropylene system from Cosmoplast can be used for: Hot and cold potable water piping networks in residential and commercial buildings. i.e. hospitals, hotels, offices, school buildings etc. Chilled water networks in oir conditioning systems, as an effective light weight and corrosion free substitute for steel pipes. Transport of wide range of chemicals inthe industry. Inigotion systems for gardens. Piping networks for rainwater vilization systems. Piping networks for swimming pool facilites, Compressed air installations. Cosmoplast Plumbing SystemsFEATURES OF COSMOPLAST POLYPROPYLENE SYSTEM + Extended durability due to the high resistance to aggressive elements, + AService life in excess of 50 yeors + Smooth and porosiy-fee intemal surace of both pipes ond fitings thus resulting ina very low pressure loss and tabsence of incrustation {reduction of section due to the limestone and scaling } + Non-toxic and physiologically harmless material + Resistance to bacterial attack thus enabling safe potable water distribution, + Resistance to wide range of chemicals, therefore no corrosion in service lines. + High impoe! strength + Heat preservation and energy -soving abilities. The heat conductivily of PP-R pipes are much lesser than metals and hence offer significantly lower levels of heat loss for transporting fluids. + High acoustic insulation against fuid noise. The fluid flow and hydraulic shocks within the building create noise which con be avoided by use of the noise absorption ability of PP-R materials, + Light weigh! easy o hondle material compored fo the metallic piping systems { 1/9 of he steal specie graviy + Convenient and reliable instllation methods. The PP-R pipes can even be installed in suspended form under ceiling without problems of deflection. + Easy interconnection over a complex network. *+ No perforation caused by electrical currents, + Cost effective pipeline network. + Sofe environment as PPR is a recyclable material. ds i ‘The PP-R system from Cosmoplast - A safe, tough, easy and cost effective solution for hot and cold water opplications. Piping System for Hydro-Sanitary ApplicationsSTANDARDS: Cosmoplast PP-R system is producted according to the following German Standards DIN 8077 Pelyrorlne Pipes: Diversions IN 2078 Poypropine Pipes: Tsing Nahods DIN 1988 Drnkng water Suey Sms IN 16962 Palyproplee Feng: Gualiy Contos ond Connatons DIN T6926; Thermos Pipes Pps Connecions DIN A107 ‘Sound eloion in Buldng Corsrtone DIN 2076 ‘etal Tread Joins Tsing Mehode DIN 2999 [ua fo ings wihTheosed Mevalicaare vs7206 Regilatons or he Wong of Thematic Mail DWS207 Welding of Tarmoplaic Marea by maone of Healing Tole 150 15874 Posts Piping Systm for Hot and Cold Water Inslons MECHANICAL & THERMAL PROPERTIES OF PPR. UNIT fanned VALUE Density a $28°C fer 1s0.1783 0.909 Melsow index (MER 250/2.16 /0min 180.1133 0.30 Volume av 23072.16 en /1Omin 150.1133 0.38 Yeld Stress {50min MP 150 827/142 25 Yield Extension (Omi) % 150 527/142 13 Tonle E. Modulus (secon Ma 150 527/142 850 Indenmation Hardness (32N/308) Ninn 150 2039/1 a7 Shore Herdness {Bec wake] DIN 53505 s Notched Bar Test +286 Ku IN 53453 2% Toughness at Kijnt DIN 53453 8 tho Inpact Kut IsO180/C od a int isoTBO/C 160 Kn IsO1B0/C 28 rod Inopoct| unt IsO1BO/IA 30 “Toughness ot evn SOLA g Kin? I5O180/1A 18 Vat Softening vST/AV50 °C 's0 306 132 Temperaure vsi/e7s0 *c 's0 306 @ Thermal Dimentonal HOTA “c 150 75/142 ” Seblty HOTB c ISO 75/142 70 Loratudinlcooficion’ of expansion mm ON 59752 018 Thermel conduciiy af 20°C Wink DN 52612 024 Specticheotat 20°C Wi/Kok adi colorimeter 20 Cosmoplast Plumbing SystemsPRESSURE AND TEMPERATURE: ‘The following table shows the expected life span of Cosmoplast Polypropylene pipes and fittings at various selected pressures and temperatures as per DIN 8077 /8078 Standard,REGRESSION CURVE OF PPR: 805 0 Pl oe 40" at LL | 28 7 TF = uo 9 ~ ae ~. = oH Sit 4 0° tll Zz ie TH SE 5% ROE = — S 3 £ ~ DIAGRAM(1) & ,, = rin & wy ge = Sao 4.) c & Z 60 40. I» 20+ ost 10 eas | ! wo toa OH tas at years 11-4years Soyears DURATION TIME (HOURS) QUALITY CONTROL: Cosmoplast PP-R systems are produced through a well laid down process consisting of systematic inspections on incoming row materials, process monitoring, ric! testing ond final inspections. Furthermore Cosmoplastis a on ISO 9001 certified company with a state of the af QC laboratory to conduct all required tests on the pipes and fitings inorder to ensure that they comply with the respective international standards to which they ore manufactured. Cosmoplast Plumbing SystemsPIPES SPECIFICATIONS ‘Cosmoplas! PPR pipes ore manulachred aecording fo DIN 8077 and DIN 8078 cond hey ore produced in diferent pressure ratings and composons PN20 Plain PPR pipes: Moteial eek 80 4 Presse Rating N20 oR 6 Standord DIN8O77 / DIN8O78 /150 15874 Application Fer hooting sysams, ha ond cold wale syslems in domes, commercial and indus bulsings oo BUNT rer Py my fo | 25542 2s 42 | I 40x67 0 67 | 50x82 50 0a | 43x 105 3 10s | 75.125 75 as I 901150 0 150 | Tox 18.3 Te ea 125208 125 208 1605266 160 266 PN16 Plain PPR pipes: Morel PR 80 Prossue Raing + PNIG sok 7A Stondard DIN077 / DINBO78 /150 15878 Applcaon Foc heating systems, hot and cad weter systems. Mail or domestic applications com AMEE, rer uncon my a) 20x28 20 28 2503.5 1 25 as axa 22 44 2On55 | 40 5 50x69 50 o eax86 | ms as 90x12 I 90 naa Ho «15.1 no 15. 125x171 [ 125 17 140x219 140 219 Piping System for Hydro-Sanitary ApplicationsPN25 PPR / AL / PPR Stabi Pipes: Moterial PPR 80 wih intergrated alminum bayer Pressure Rating PN25 Standard DIN8077 / DIN8078 /150 15874 Appleation soniary and heating systems in domestic, commercial nd indusvil buldings PN25 PPR / AL / PE UV Resistant Pipes: Material PPR 80 with intergrated aluminum layer and exremal Polyethylene layer Pressure Rating: N25 Standard DIN8O77 / DINBO78 /'s0 15874 Application for extemal expoted insllaions for sanitary and heating systems in domestic, commercial anc indus buildings Dimensions of PPR / AL / PPR and PPR / AL /PE Pipes: - KY sg ‘8 oT inn or 70x34 20 2160 a “4.10 25x42 25 7680 42 510 B2n54 2 3380 54 4650 20x67 2 200 67 a0 30x83 30 5200 #3 1010 ex105 a 6500 10s 1370 754125 7s 7700 ns 15.10 990x150 %0 97.00 150 13.10 Vox 189 io 11.00 aa 72.10 eA rR paseo pt nm Cosmoplast Plumbing SystemsPN25 PPR / FG / PPR Faser Pipe: Material PPS 80 with intergrated fiberglass layer Prossue Rating > PNRS oR 6 Standard DIN8077 / DIN8078/1s0 15874 Application sanitary and heating systems in domes, ‘ond industrial buldngs cory rr) nd oo oc) 20x34 20 34 25x42 25 42 82x54 2 54 40x87 © 67 50x83 50 83 63105 a 105 75125 75, 125 90x150 30 150) 10x 183 10 183 125x208 135 208 160266 160 266 PN20 PPR / FG / PPR Faser Pipes and PN 20 PPR/FG/PPR UV Resistant Pipes (For Exposed Installation) roy or Toy ed i) co) 20x28 20 28 25x35 25 as 32xAd 2 44 40x55 ry 55 50x69 so 69 x88 3 36 75x 108 75 103 90% 128 90 123 Nox 15.1 no 151 1254171 125 7 160x219 160 219 = PN2OPPRFG PPR UV Resistant Pipes ee aalbefor sizes upto 110mm ony Piping System for Hydro-Sanitary ApplicationsLONGITUDINAL EXPANSION: The following schemes demonstrate some important coses: PE= Fixed Point; PS= Sliding Point Exposed Installations: Longitudinal expansion depends on the temperature variation the pipes ore exposed to. If the working temperature of the system undergoes variations up to 10 -15°C the pipe elongation should be evaluated and considered. Cold water pipes have low linear expansion and hence con be neglected. But in case of hot water ‘ond heating installations, the longitudinal expansion must be considered and the installations must be planned ‘ond performed accordingly. ‘Thermal expansion of Polypropylene pipes can be evaluated using the following formula AL = axLx At Where AL = Lineor expansion in mm. = Cootcient of linear expansion = 0.18mm/mKk L = Iritol pipe length in m. At = The difference between the temperature al which the system i installed and the operating lemperalure. Compensation of Longitudinal Expansion: For exposed installations, the length variation due to longitudinal expansion should be compensated by calculated and olanned change of direction. The free pipe length “Ls” is the length of pipe that should be kept free without clamping so as to compensate for the expansion. iis calculated with the following formula Ls=Kx VExAL Cosmoplast Plumbing SystemsWhere: Ls = Free pipe length in mm AL = Linear expansion in mm d= Edemal diemeter of pipe in mm. K = 20 Constant for the PP.R material Example IVa pipe of 25mm diameter with 4m length, undergoes @ potential temperature variation of 50° C. The thermal ‘expansion calculations result the following: ‘The variation in length AL = axle at = 0.18% 4x50 = 36mm The free pipe length: ls = KxVdxAL = 20xV25%36 = 600mm The longitudinal expansion of plain PPR pipes can be token direcly from the below table Pipe length in metres 3 ose 108 18 26 2 a ae an os 8 1 27 36 as sa o 72 08 108 216 3 a 4 oa 756 we o7 126 252 ae soe o 756 a a8 oe 1a 2 a 576 7 1 1098 1s 7 a ie oe 72 2 1a 1s rz #0 14a aa a2 sr a wa 08 52 100 1 ue se n ” vo 6 ve Piping System for Hydro-Sanitary App!‘The longitudinal expension ond free pipe length can be token from the below diagram tor 20 30°40" 50" 60" _70° / PIPE LENGTH (m) (0 10 20 30 40 50 60 70 80 0 100110120 130140150160170 180 Imm Ls (cm) no 120 130 vor DIAGRAM (2) 150 160 170 \ 120 190 200 225mm 210 220 230 @32mm 220mm 240 250 260 270 280 290 300 310 320 8 60mm 330 340 350 275mm Biiomm — B95mm 2 40mm 250mm ‘MINIMUM COMPENSATION SPACING FROM THE DEVIATION TO THE FIXED POINT Cosmoplast Plumbing SystemsB. Concealed Installation Concealed installaions generally do not require any special consideration for linear expansion os there is enough room to accommodate the expansion of the pipe as per the guidelines of installation according to DIN 1988. Where there is no room to accommodate such expansion, the material absorbs all the siress arising from residual expansion. PIPE SUPPORTS: When pipe clamping techniques are considered, two types of clamping joints must be identified; fixed points and sliding pon’. Fixed clamps hold the pipes in a rigid manner, while o sliding point allows the pipe to move in the axial direction of the pipe, Faxed points divide the pipe network into individual sections. Given this, the possible longitudinal exoansion and the corresponding free length from the fixed pipe points must be calculated Sliding points should be located so thatthe axial movement of longitudinal exoansion is not influenced by the fixed connection points. Given this, the sliding Points should not be installed on either side of the fittings in order to avoid acting os fixed points itis important, thatthe clamp or festening material does not damage the surface ofthe pipe. The ideal fastening material {for PP-R pipes are rubber lined clamps which ensure that no mechanical damage ofthe pipe surface can occur The following table shows the effective spons between clamps for horizontal lines at selected temperature differences: Ertonne rte) 2 129 % % 85 80 75 70 40 145 0 10 30 99 85 80 50 179 130 120 10 na 100 5 o 190 150) 140) 130 120 ne 109) is 210 160 150 7 130 120 no 90 220 160 160 150 150 140 125 ni 250 180 180 170 170 160 140 Piping System for Hydro-Sanitary ApplicationsPRESSURE LOss: ‘The choracteristcs of PPR moterial enable to obtain ot the extrusion phase very smooth walls (roughness = 0.0076) which reduces the friction losses and improves the performance of the whole system. These factors allow Using higher water speed in the circuits without having negative effects in the system as the case in other piping systems. The maximum allowed speed for cold water is 5 m/s, while for hot water (higher than 70°C), itis advisable not to ‘exceed 3 m/s. The pressure losses in PPR can be token directly from following diagrams: Pressure Loss Diagrams: fw Wa 8 888 Presureloss Pa/m,(10.000 Pa=0,1 ber 1 m.ca) Cosmoplast Plumbing SystemsPressure Loss Table for Pipes: PN 20 & PN 25 at 20°C Ra | f ‘cor | 02 | oar | cco | ooo | ogo | 000 | 000 oo ¥ 0,07 0,05 0,03 0,02 0,01 0,01 0,01 0,00 z 27 | 10 | 00s | oor | 000 | ogo | aco | 000 om ¥ Os 0,09 0,06 0,04 0,02 0,01 001 0,01 oo & oo | 20 | o0e | ace | oor | 000 | a0 | 000 : oz | oa | 008 | ons | 00s | om | om | om oo a om | oa | oro | one | oo | 090 | 000 | 000 5 oz | ore | om | oor | 005 | oon | cae | om ® ve | 047 | ons | 005 | oe | om) | 000 | 000 oes ¥ 0,37 0,23 0,14 0,07 0,06 0,04 0,03 9,02 z 202 | 047 | 0ar_| oor | 002 | oar o00 | _a00 one ¥ 044 0,28 O17 O11 007 0,04 0,03 0,02 oor z 265 | oa | oar | oop | 002 | oar | aco | 000 5 esr | oa | ozo | ora | oo# | 00s | aoe | oma on z as | maa | oas_ | or | 00 | oor | oar | 000 5 ose | oar | 02s | ore | 007 | 096 | aoe | ons co z ais_| 19 | 04s | are | 005 | 007 | om | ono : ae [042 [025 | ore [ono | 008 | 00s | ons z soa [ 1s [ear | em [eos [eee fear) enn aa ¥ 078 046 0,28 018 O12 0,07 0,05 0,04 z a7 _| 2a | om | oz | oo | aa | oa | 000 ov ¥ 0,88 055 0,34 0,22 O14 0,09 0,06 0,04 on z om | aoa | os | om | on | om | om | oo 5 vz oss | 040 | 025 | 016 | 010 | 007 | 005 ci z vrs | aas_|iae_| 040 | ore | oo | oon | ot Y v7 ora | oas | oa7 | ore | 012 | 008 | 006 = [se | «77 | tas | 0a | a7 | ons | 002 | oor ca ¥ 1,32 0,83 0,51 0,32 0,27 013 9,09 0,06 = [ae [sar | 176 | 059 | 020 | oor | a2 | oar on v 146 0,92 057 0,36 0,23 O14 0,10 0,07 - a | wae | vor | 366 | 122 | one | or | 006 | oan ° ¥ 219 139 085 054 0,35 022 O15 oN co «| 095 | vse | ois | 205 | 070 | 029 | 010 | 00 5 zm | ias [113] ore | 04s | 029 | 020 | 014 ono =| 760 | sas | om | 07 | tos | ose | ons | 006 yi ass | 2a | 142 | ono | ose | 036 | 025 | 018 2 [17a | ae | 1300 | 428 | 1ae | 047 | 020 | 008 oe ¥ 438 277 170 1,08 0,69 043 9,31 0,21 Flow rete (U/S), R= Pressure losses (mbar/m),v = Flow speed (m/s) “Pressure lose tbl fr ngs canbe provided as per cular aqueCOSMOPLAST COMPOSITE POLYPROPYLENE PIPES: The technology of Composite PPR pipes has been developed due to the increasing need for PPR pipes that can be used in applications where the normal plain PPR pipes can not be implemented. This composite technology could offer easy solutions fo the expansion of PPR pipes and fo the UV exposure in case of external installations. (A) Cosmoplast PPR / AL / PPR Stabi Pipes The Polypropylene piping industry has been witnessing major innovations in recent fimes and in order to cater to the need for these innovative products, Cosmoplast has extended its polypropylene product range with the addition of a new Polypropylene (PP-R) / Aluminium (Al) composite pipe. This new pipe system comprises of an aluminum layer, integrated within the polypropylene pipe structure. This innovative product is thus made of a unique combination of materials with each ‘adding their own benefits to the final product. Cosmoplost PP-R/ Aluminium/ PP-R composite pipes for ho! and cold water distribution systems are suitable for high pressure potable water disibution systems in addition to a wide range of other hydro-sanitary applications and will provide an operational service life in excess of over 50 years. The exceptional reduction in thermal expansion of the PP-R/AI/ PPR composite pipes makes this product an exiremely reliable and stable product for use in ho! and cold water applications. Cosmoplast PPR/AL/PPR Stab pipes are manufactured according othe standards DIN8077 and DINBO78 , PN25 Fields Of Applications: Cosmoplast composite PPR/AL/PPR pipes are used for * Holand cold pojable water networks in esidotl industri and commercilbuligs. hospital, hoes, schools, offices, factories etc + Chilled water networks in Air Conditioning systems providing an effective light weight and corrosion free substitute for stee! pipes. + Transportation of wide range of chemicals within industrial processes. + Piping networks for swimming pools facilites. + Compressed air installations {B) Cosmoplast PPR / AL / PE Pipes, UV Resistant for External Installations PPR pipes are ofen used for external exposed insallatons, in which case the pipework has to be insulated to avoid direct exposure to UV light which may damage the pipes. CCosmoplast PPR/AL/PE. UV Resistant composite pipes are the easy soltion for exiemal installations due to the innovative combination between PPR, Aluminium and Polyethylene. This technology is very similar to the Stabi PPR/AL/PPR technology, however the exemal layer is made of polyethylene instead of PPR. This external PE layer provides the necessary protection tothe PPR pipe due to Cosmoplast Plumbing Systemsits superior characteristics that enables it fo resist direct exposure to sunlight [UV]. Cosmoplast PPR/AL/PE UV Resistant pipes provide the same outstanding performance as PPR/AL/PPR Stabi pipes in terms of reducing the thermal expansion, thanks to the aluminium layer integrated in the structure of this pipe. Therefore PPR/AL/PE. UV Resistant Pipes can be used for the same applications as the PPR/AL/PPR Stabi pipes in addition to the exposed external installations. Cosmoplast PPR/ AL/PE UV Resistant Pipes are manufactured according to the standards DIN8077 and DINBO78 , PN25 (C) Cosmoplast PPR / FG / PPR Faser Pipes Cosmoplast PPR/FG/PPR Faser pipes are composite pipe consist of an integrated middle layer of special formulated fibregloss (FG) impeded between an internal and external PPR layers. The presence of fibreglass layer increases the strength of the pipe in such a way thatthe pipe can be produced as SOR 7.A but with pressure rating of PN20 instead of PN16, which means bigger ID and higher flow compared to SDR 6 PN20 pipes. The expansion of hese pipes is alo reduced to a almost the same expansion of PPR Stabi pipes. Cosmoplast PPR/FG/PPR Faser pipes are manufactured according fo the standards DIN8O77 and DIN8O78 , PN20, SDR 7.4.and SDR 6 PN 25 COMPOSITE-TECHNOLOGY: With the PPR/AL/PPR/Stabi PPR FG PPR Faser Pipes and PPR/AL/PE UV resistant pipes the, linear thermal expansion is reduced by at least 75% when compared to standard PPR FG PPR Faser Pipes PPR pipes and hence has the following characteristics + The coefficient of linear expansion is almost identical to that of metal pipes. + In comparison with other plastic pipe systems the supporting clamp intervals can be increased leading to a reduction in the number of mounting clips being used, + Optimum cost-performance ratio in comparison to metal pipes. + Lower weight than equivalent meal pipes. + High impact strength. Piping System for Hydro-Sanitary ApplicationsEFFECTIVE CLAMPING DISTANCES: Effective clamping distance for Composite PPR/AL/PPR Stabi Pipe, PPR) PPR Faser Pipe and PPR/AL/PE UV resistant pipes EN) ct co 20 5 1s: 25 18 125: 22 9 15 0 215 Ww 50 24 1 6 2.85 2.15 185) 18. 75 28 22. 2 195; 90 a 23 2a 2 110 325 25 2 2 EXPANSION OF PPR COMPOSITE PIPES: The expansion of composite PPR/AL/PPR Stabi Pipe, PPR/FG/PPR Faser Pipe and PPR/AL/PE UV resistant pipes are 75% less than the normal PPR pipes. as noted in the below table. eee ‘Tomporature difference A ¢(°0) 02, 0.08 OH 018 O24 030 086 042 48 03 0,09 018 027 0.36 05 0.54 043 072 OM) 072 24 0.36 on 0.40 072 0.84 0,96) 05 05 0,30, 0.45 0,60 075 1.05: 20 08 08 036) 054 on 0,90 1.08 128 1a 07, 02) 0.42 063 0.84 1.05; 26 147. rm 08) 024 08) 072 096) 1.20) 1a 168 192 09 027 0.54 08 08 1:35) 62 189) 26 10 0.30 060) 090 | 0,120) 1,50) 1.80 2.70 240) 20 0.40 20 240 3,00 3.80 420 480 30) 0,99 180 3.80 450 540 639 720 40 1.20) 240 480 600 720 2.40 9,60 50) 1,80) 300) 600 7.50 9,00 1050 | 12,00 ry 1.20 3.40 720 9,00 020 | 12.80 4.40 78) 20 420 840 woso | 1240 | 1470 | 1620 80 240 480 9.60 12,00 16.80 9,20 20) 270 3A0) a0 yoao [1350 | 1420 | tao | 2160 100 3.00 6.00 9.09 200 | 15,00 00 | 21,00 | 24,00 Cosmoplast Plumbing SystemsFUSION WELDING PROCESS Cosmoplast PPR pipes and fitings are jointed using heating process called fusion welding. The process is very simple and resuls in inseparable watertight joins. Wis cared out using @ electric fusion welding machines that simultaneously het the intemal suface ofthe firing and the external surface of he pipe ‘which are then joined together to form inseparable water fight join. The following sections demonstate the basic procedure for fusion ‘welding process for plain and composite PPR pipes. Welding Plain and PPR / FG / PPR Faser pipes: The following steps describe the steps ofthe welding process: 1. Prepare the welding machine by fiting itwith the welding dies of the diameters to be welded. Connect the plug to the 220 V power supply socket and wait until the ‘machine reaches the working temperature (260°C } 2. Cut the pipe at right angles to the pipe axis using suitable pipe cutter. 3. Remove any burrs or cutting chips by deburring the cutting oreo. 4. Mork the welding depth on the pipe using a suitable morker. 5. Without turing insert the end of the pipe into the heating sleeve up to the morked welding depth and a the same time slide without turning the fitfing into the cher side of the heating tool up to the stop. = Leave the pipe ond filing on the heating tool unil the 7. At the end of the heating time, remove the pipe and fitting from the heating tool and push them immediately info each other up to the mark indicating the welding depth. At this stage the depth mark will be covered by ‘he welding bead. During this process, do not rotate the pipe ond fing relative to each other 8. Allow the joint to coo! fully before using, Piping System for Hydro-Sanitary ApplicationsWelding Composite PPR / Al / PPR Stabi and PPR / Al / PE UV Resistant pipes: The welding process of composite pipes is identical to that for plain PPR pipes. However, the external and inlemediale kyers $hould fst be shaved off before proceeding in the fusion process. The following sieps describe he steps of he welding process 1. Prepare the welding machine by iting it withthe welding dies of the diameters to be welded. Connect the plug to the 220 V power supply socket and wait until the machine reaches the working temperature (260°C } 2. Cut the pipe at right angles to the pipe axis using suitable pipe cutter Remove any burts or cuting chips by debuting the cutting area, 4. Use the pipe shoving ool io peel off he outer layer {PPR in ‘case of Stabi pipes or PE in case of UY resistant pipes and the intermediate aluminum layer. This can be done by fully pushing the end of the composite pipe inside the shaving tool until it reaches the stops inside the shaver. tis not necessary to mark the welding depih os the stop inside the shaving tool ses the correct welding depth 5. Without tuning insert the end of the pipe into the heating sleeve up to the marked welding depth and at the same time slide without turning the fitfing into the ther side of the heating tool up to the stop. 6 he pipe and fiting on the heating tool until the ime is elapsed. At the end of the heating time, remove the pipe and {iting from the heating tool and push them immediately info each other up to the mark indicating the welding depth. At this stage the depth mark will be covered by the welding bead. During this process, do not rotate the pipe ond fitting relative to each ofher. 8. Allow the join fo coo! fully before using 20 5 4 2 2 7 4 2 32 8 6 4 40, 2 6 4 50 18 6 4 @ 2 8 é 75 30 8 8 90 40 a a 110 50 10 8 125 60 10 8 160 100 10 10 Cosmoplast Plumbing SystemsElectro-fusion Welding Process ‘The electrofusion welding process is used for emergency repairs or when welding has to be done in small places on positions not assessable by the polfusion welding machine. ElecroFusion process is carried out using special welding machine ond PPR ElectoFusion sockets. The Electtofusion sockets ate provided wih 2 socket ends that can be welded in a single operation. The ElectoFusionsockesinchde bul in rsitonce collin her body, he welding machine sends curen!hrough he restonce coil hat cause the PPR material to melt ond therefore the two sides of he socke ond the pipes ore fused together atthe same time. The electro‘usion sockels have stops on ther inlernal suface up to which he pipe should be inserted inside the socket. These stops can be removed with sharp blade in cose the electrofusion sockets ore to be used as sliding couplers. The electrofusion sockets have two pins on the external surface, to which the welding machine is connected while performing the wolag proces. The wo indices wl oppeor dng the woldng proces fo indict ta he wong tempera hos reached ‘Abu fn te section proces, tw nal mae fhe scat andthe alsin of pipe lb hed together. Qualy electofusion joints ore guaranteed only if he socket and pipe surfaces ore free from moisture, cit and grease, The electrofusion process is done os detailed below: 1. Cut the pipe at right angles to the pipe axis using suitable pipe cutter, 2. Clean the parts ofthe pipe to be welded ond the fiting in order to avoid any dust or sond that might damage the quality ofthe joint «Remove the walding electrofusion sockets from their protective packing and immediately fit the pipes ends inthe welding socket; the correct depth of connection is when the pipe touches the stops. |. Hold the pipes in their position during the welding process, 5. Connect the welding machine to the welding socket tnd stort the welding machine. The springing out of the Iwa indicator pins indicates that the heating time hos ended, 6. Disconnect the welding machine from the welding socket. 7. When welding is completed, itis recommended not to apply ony mechanical stress {by deflections, torsions, ‘ractions) to the joint for at least 20 minutes Note: Eleclo Fusion process is apalicabe for pipe fo pipe connection onl ing System for Hydro-Sanitary ApplicationsHANDLING, STORAGE AND TRANSPORTATION re considering the resilence of these pipes and fitings. Transporation, storage and nthe below rections and precavions pipes and fings should be handled wth hendling should be done faking info cons Handling + Tate alrearonable care when handing PPR, pottcultly in very cold conditions when the impact srength of he mmoterialis reduced, ‘© Dornot throw or drop pipes, or drag them along hard surfaces © Do net se pipes against hard surfaces or drag them along the ground) ‘+ Incase of mechanical handling, use proleclive sings end padded supports. Metal chains and hooks should nat moke conta! wih he pipe ‘+ PPR Pjpge& filings should be stored in covered areas away fom diac! sun Ight © Teavidd height of | Sm salon eve ine, plas should be sacked on a flat bose ot on level ground wth maximum slack 1+ Provide side suppor at Im cantar + Sie all material in wellventlaed, shady conditions in covered sores + Avoid direct exposure to sunlight for long periods ‘+ keep pipes in their nylon packing and fitings in their original packaging unl requited for use ‘+ deal, stacks should contain one diameter pipe size only Where this is bose of sac posible, sack largest diomelar pipes at © Donot plice heavy tems on top of he pipes ‘© Pipes should be kept cleon or much os possi, asthe may sa ing time whi pee for welding. pa end fitings shoul be covered with proper shoo + While stows ot sta or dung temporary storage outdoor, PPR Pi for protectin fom UV. Cosmoplast Plumbing SystemsTransport + While ranspon, pipes should be aronged safely on tucks avoiding cxosing, bending and over stacking. ++ The pipes should oo be fully supported ove ther total long. ‘+ Proper protection should be provided if chins or cords ar used toe down the lood in order o avoid damaging he Pipes. SUGGESTIONS FOR THE CORRECT HANDLING OF PP-R SYSTEM: «Handle Pipes with care, and avoid hard impacts atthe end of the pipes. + Use suitable sharp cutting tools to cut the pipe with no burs ‘+ Dornot ins! the pipe or the fiting ater joining together. Alignment up to 5 degrees relative to the axis of the pipe con be done immediately afer joining, ‘+ Protect the pipes from sunlight ond rain during storage and on site. + Dornot use a flame fo bend the pipes; heating with hot air up to 140°C can be used when needed. + Use Teflon sealing topes where necessary. «Avoid heowy and sharp loads on the pipes. ‘+ Follow the instructions for joining process. ‘+ Follow the right techniques for expansion compensation. + Always protect the pipes from direct exposure fo sunlight by proper insulation or painting + When connecting two threaded fiings, use reasonable quantity of teflon sealing tape and avoid using excess quanti. Piping System for Hydro-Sanitary ApplicationsPRODUCT RANGE CCosmoplast PPR pipes fo DIN 8077 /DIN 8078 ISO 15874 and fitings to DIN 16962 / ISO 15874 PN 25 oN Cosmoplast Plumbing SystemsPRODUCT RANGE PPR PIPES ha Piping System for Hydro-Sai ary ApplicationsCosmoplast PSU 25 /25 20 34 PSU 25 /25 25 42 PSU 25 /32 2 54 Psu 25 /40 ry 67 PSU 25 / 50 50 33 PSU 25 /43 6 105 PF 20.20 20 28 PF 20-25 25 a5 PF 20.32 32 44 PF20-40 40 55 PF 20.50 50 69 PF 20-69, a [a6 PETS. 10.4 75 103 PFIO- 15.2 10 | 151 a 7125208 PN 25 PPR FITTINGS Cosmoplast Plumbing SystemsPiping System for Hydro-Sanitary ApplicationsCosmoplast Plumbing SystemsREDUCER SOCKET F X F a. Piping System for Hydro-Sanitary Applications Ne, ro PRS. 2520) 2520 560 P.RS.3220 32x20 390 PRS 3225 32x25 360 PRS 4020) 40x20 200 PRS. 4025 40425 200 PRS 4032 40x32 14a P= RS- 5020) 5020 200 PRS. 5025) 50x25 120 PRS 5032 50x32 120 PRS 5040) ‘50x40 0 PRS 6320) 6320 20 PRS. 6925) eax25 0 28S 6392, 63x32 0 PRS. 6340 63x40 0 PRS. 6250 62x50 0 P:RS-7532 75x32 0 P= RS-7540 75 «40 o PRS. 7550 7550 o PRS 7563 75% 63 4 PRS. 9032, 90x32 0 PRS. 9040 9040 38 PRS 9050) 90x50 36 PRS 9063 90x63 6 PRS. 9075) 90575 2 P-RS- 11050 110%50 20 PRS. 11088 Tioxe 20 PRS. 11075 Mox75 2 PoRS- 11090 Ti0x90 15 PRS 125110 125% 110 10 PRS 160110 160x110 8 PRS 160125 160125 6 P=EC-20 20 1200 PEC.25 25 2 P-C.32 2 315 PoEC-40 40 200 PEC-50 50 160 PeC.63 a cy P-EC-75 75 48 PEC-90 90 2 P-EC-110 no 20 PEC. 125 125 4 PEC 160 160 7Cosy at No aa P-CR-20 20 300 Peck 32 2 100 F-ck 40 40 0 cs 98-20 20 80) P0825 2 100 88-32 2 oo Aad Cu oe LONG BRIDGE Cosmoplast Plumbing SystemsP-MS- 20% 20x15" 150 PMS 20% 20x 100 PeMS- 2514 xe 150 PoMS.256 Bw 120 PoMS- 32% axe 100) PMS. 32 oe 0 PMS 32) 32x 1" o PoMS-201%8 Boxe 30 P=MS- 501 50x 1 24 PeMS-632 xe 2 P-MS- 7526 75x26" PMS 900 xe PMS 1104 Toxé P-F5-201 0x4" 200 PFS 20 200 150 PFS 25 25 180 PAS 25% ae 150 PFS 32K 32x 120 PFS 32 vg 120 P1532 32xI" 70 Po¥5- 401 xe 35 PFS. 501% SOx 1 m4 Ps 2 ar 4 P#5- 752% 75x20 @ PFS.908, 30x57 2 PAS 1104 Tox 7 ME-20%5 20415" 120 ME 20% 200m 100 P F P-ME-25\4 25x 100 as PME 25% Ea 0 PoME-321 xt 50 * Tea are avaabl in brass and el plated bass opens * Abtioads are SPT Piping System for Hydro-Sanitary ApplicationsCosmoplast Cai ac een acd Mbt P-fE- 205 20x" 0 P-FE-20% 20x" 160 P-FE-25% 25x15 120 PFE 25% 2 100 PFE 32K 2h 30) PFE. 32% Be 70 ? 32x" so re ar P= WE 2015 20x15" 100 P= WE- 25%: 25x 70 P= WE-25% 25x! 160 fo ean) ro P-MT-20% 20x15 200 PoMT- 25% 25x 0 PMT 25% 25%" 75 P-MT-32¥5 3x 560 PMT -220/4 a 600 P-MT-321 32x" 760 rr ar P-WG -20)5| 2015" 2 PWG 25% 25K" 15 “Altweeds we 8827 Cosmoplast Plumbing SystemsFEMALE THREADED TEE ro coo P-#T-20%8 20%" PFT 20% 2a PFT 2515 25x PT 25% ae PFT 326 we o PFT 32m Raw 0 PFT a21 32x17 2 P-BU-20% 6" x20 300 P-BU-25% ie x25 200 ?-pu-a21 Vxa2 50 PBU 4014 rao “ P-BU-501v8 1" x50 20 P8U.632 2x63 2 P-MU-20%8 We x20 130) PMU. 25% Was 100. PeMU-321 7x2 70 PMU. 401m Te xA Ey P-MU-SO1% TH" x50 2 PMU. 632 Pes 2 P-fU-20%8 x20 180) P-FU-25% ws 120 P-FU-a71 7x82 70 PA a01 Taxa a P-F-501% TH x50 0 FFU. 632 Px 16 valle n brass anniek plaledbass opons + ilteads are SPT Pi ing System for Hydro-Sanitary ApplicaP-PU-50 30 24 7-8 a 18 CRUE ros ar Orn P-£U-321 32x" RUA a CLO eg A No en) Paes P-VCH 20) 20 35 n Pvc -25 25 2 PVCH-32 2 25 _ er | * Treas ar aval in ras accel lated brass oon * Altheads are SSP 7-CU-a21% 32x 1M" | Cosmoplast Plumbing Systems-VC.20 2 0 [p-ve-2s 35 @ = 20 50 35 © 2 36 0 24 50 2 a @ 75 4 F-HWY-90 90 2 Peay. 110 0 2 PN 20 BALL VALVE WITH LEVER HANDLE (BALL COCK) P-HW. 20 P-HW- 25: P-HWV- 32, P-HW- 40 P-HWV-50 Pow 6 P-HW-75: mn POP LPL ro P-DWV-25 P-DWV- 32 P-Dwv-40) P-DWV-50) P-DWV- 63, Piping System for Hydro-Sanitary Applications P-8C-20 20 oo P8C.25 25 0 Pac -22 2 30 P-c-40 40 20 P8C-50 30 12 Pac. 63 3 é Size fn P-OWV-20 20 50 2 0 2 25 0 16 50 10 8 6P-MFU-1/2-3/4 P-MFU.3/41 YM" F Wak 20 5 2 0 50 475 o 325 P-HRC- 20 20 PHP 25 2 PRC. 32 2 PHC. 40 0 PHP. 50 50 PRC 63 3 200 700 600 700 300 240 wade Cosmoplast Plumbing Systemsco a 2 4 é , FSR 50 3 4 Po FSK- 68 a 4 > PARTS 7 a c P-F5k-90 7 @ 2 PARTI 10 = ae 7 FSR 160 160 @ P-WM- 2083 | 20.83 (helucing tools 20-40mm) | 1 P-WM- 5075 |[50:110nm (heoding took 507Smmi| P-WM- 110 | 160nim teleding teal 110-160mm) | 1 ro oa) PWM 2063 | 20431 (helucing tools 20-40) P-WA- 5075 [50-1 Om (heluding iol 5075) F-WM- 110 | 160mm {eleing tole 110-160) PWM 125 | 125-760 (Without iol) P-WT-20 20 FwT25 25 aaa PWT 32, 32 Pwd 40 PWT 50 50 PWT a PeWI-75 75 7WT- 90) %0 P-wi-110 no PawI= 125 125 PWi-160 160 Piping System for Hydro-Sanitary ApplicationsFLECTRO-FUSION WELDING SOCKETS ros Size (nm) P= EFS.20 20 Po EFS.25 25 P= EFS -32 2 P= EFS40 0 -EFS-50 50 Pes -69 a P= EFS-75 75 P-EFS.90 0 P-£f5-110 10 a ane ~~ P-PC-2040 20-40 Cosmoplast Plumbing SystemsDay &— al PPC 2063 20-63 RFC 2063 [p-we-aoii0 20-63 20 20-110 10 Piping System for Hydro-Sanitary Applications PPS 1620 16-20 P-P5-2025 20-25 P-PS-3240 32-40 PP5- 5068 50-63 PPS-75 7 F-P5.90 cy P-P5-110 no an PTF) PRESSURE TEST PUMP VWr BIE 1" GREEN PPB PTAC CUR ray e PPPs is 1700 PPP we 360 al rv 600 Note: Chemical Resistance Table for Polypyopylene can be provided as per customer request Cosmoplast Plumbing SystemscRRTIFICATEtee Cd Rarariiritct www.cosmoplast.com ) Lae i Cosmoplast Industrial Co. 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