Internal Use Only

Fireless Construction Methods

(English, Excerpt Version)

Shimizu Corporation
International Division

2015.06
 Table of contents

1. Introduction ································································· 1

2. How to Use This Manual ·············································· 2

3. Selection of Fireless Construction Methods ················ 5

3-1 Selection of Cut-off Tools for Demolition ····················· 5

3-2 Selection of Installation Methods ······························· 6

3-3 Selection of Joints and Construction Methods

for M&E Piping ························································ 7

Material 1 Materials for Fireless Construction Methods ·········· 8

1-1 List of Construction Methods by Operation ·················· 9

1-2 List of Tools • Construction Methods ··························· 13

1-3 Knowledge of TIG Welding ······································· 20

Material 2 Materials for Hot Work ······································ 21

2-1 Knowledge of Fire ··················································· 22

2-2 Knowledge of Inflammable Materials ·························· 23

1. Introduction

On construction sites, we are always at the risk of a fire occurring. If a fire

accident occurs during construction work, not only it causes a lot of trouble
to clients but also it creates a large impact to the society as well as affects
all aspects of QCDSE greatly for the project site.

Particularly renovation work requires working in a space where flammable

materials are already installed, which makes the risk of a fire occurring
even higher. This is why renovation work should be carried out with “fireless
construction methods” at our company as a general rule.

Accordingly, we need to unite and do our best to carry out “fireless

construction methods”, including design problems.

In adopting fireless methods, it is necessary to obtain the construction

conditions at the estimating stage and consider the most suitable method
so that we can make adjustments to the schedule and the budget in
advance.

With regard to installation, in cooperation with the building manager and

the designer, we need to conduct in-depth discussions, form plans with
close attention, develop rules to prevent a fire occurring, and follow these
matters without fail.

October, 2014

-1-
 2. How to Use This Manual
In this manual, methods are graded into 3 phases according to how fire is generated.
Grade A is a fireless method which doesn’t generate flames or sparks, whereas Grade B
and Grade C are hot work methods.
Table 2.1
Grade Condition Type Method
A Flame or spark is never generated Saw cutting Fireless method
Sparks occur due to the friction of Grinder cutting Hot work
B
steel material
Hot work (Molten metal or sparks) Welding, Hot work
C
Fusion Cutting
The selection process of fireless methods is shown in the flowchart. Also, the procedure
and how to use this manual are shown in the table below.

Start
Figure 2.1 Flowchart of reviewing
alternative methods to hot work
Extract works which might generate fire

Hold a meeting to consider “Fireless Methods” Consult Design Dept./Technology Dept.

Relevance of fireless designs

Draw up hot work plan
• fireless methods NO

YES Obtain approval

Carry out fireless operation Carry out hot wok

Table 2.2 Procedure to select method and How to use this manual
Procedure to select fireless method How to use this manual
① Extract works which might generate fire from each ▪Review work contents, tools, and subcontractors using
construction stage. [Construction Method Review Sheet].
② Consider Quality, Cost, Schedule, and Safety, and ▪Examine referring to [3. Selection of Fireless
examine whether the extracted works are relevant to Construction Methods], [Material 1. Materials for
Grade A Method (Fireless method). Fireless Construction Methods] or opinions of
subcontractors in charge of the works.
In case the method is Grade A ▪Establish construction plans referring to [3. Selection
③ Carry out “Fireless method”. of Fireless Construction Methods].
In case the method is Grade B or C ▪Seek opinions widely from company staffs (Design
④ Hold a review meeting to consider “fireless method”. Dept., Technology Dept., Safety Dept. etc.) or
subcontractors, and conduct reexamination.
⑤ Reexamine if it’s possible to carry out fireless
designs or fireless methods.
⑥ In case fireless method cannot be carried out, ▪Establish construction plans referring to [Material 2.
consider methods that generate minimal fire or fire Materials for Hot Work], and draw up the hot work
protections, and plan installations with hot work. plan.
⑦ Draw up the hot work plan.
⑧ Submit the plan to obtain approval by the
predetermined approver.
⑨ Carry out installation with hot work methods.

2
 Table 2.3 Construction Method Review Sheet < Example >

Demolition/Removal involved in Relocation of ❍❍Bank ❍❍Branch & Pharmacy Interior Work

No. Work Work Items Work Contents Grade Grade Subcontractor Tools to use
Bank Interior
Removal Work
1. Demolition ▪Dismantling vault ▪Removing volts, Dismantling, Kumahira
Carrying out A
▪Chipping around exterior ▪Chipping around anchor bolts, Yushin Kogyou Disc sander
fittings and removal and cut with a disk sander A
▪Removal of ceiling and ▪Dismantling manually Okuju
partition walls A
▪Removal of ▪Dismantling manually, Partially with Shinryo Jig saw
air-conditioning facility electric saw A Corporation

2. Staircase ▪Demolition of concrete ▪Cutting re-bar Yushin Kogyou Gas welding → Cut by re-bar
Structural work staircase frames C A cutter (Leaving edges)

3. Store Interior ▪Installing exterior ▪Arc welding to frames Sanwa Shutter

Work shutters, steel doors C
▪Installing steel frame ▪Installing stairs and handrails Sanyu Kenzai For appearance, arc welding to
staircase A handrails

▪Newly installing ▪Assembly of steel-frame Sanyu Kenzai Partially on-site welding

dumbwaiter substrate, arc welding partially A C Arc welding

▪Installing light-weight steel ▪Reinforcing openings Okuju Specialized clamp, Riveter, Chip
substrate, walls, ceilings ▪Reinforcing swing stop A saw high-speed cutter for
processing materials
▪Installing Air conditioning Shinryo Refrigerant piping joint
facility C Corporation blowtorch

Grade A: Method which doesn’t generate fire, B: Method which generates a small amount of fire, C: Method which requires use of fire

3
 Construction Method Review Sheet
Work

No. Work Work Items Work Contents Grade Grade Subcontractor Tools to use

Grade A: Method which doesn’t generate fire, B: Method which generates a small amount of fire, C: Method which requires use of fire

4
3. Selection of Fireless Construction Method
Generally, when materials made of metal are removed or newly installed, we depend on
fusion cutting or arc welding. However, we have to consider alternative construction
methods to hot work fundamentally in order to prevent fire incidents caused by hot work.

3-1 Selection of Cut-off Tools for Demolition

In any case, it is important to select the most suitable cut-off tools when you draw up work
schedule, cost estimations, and budgets because work efficiency and costs are greatly
influenced.

a. Cutting Reinforcements
To cut reinforcements, you can use a hydraulic cutting machine and an electric cutting
machine (reinforcement cutter) which is capable of cutting D16~D29. For cutting
reinforcement in a tight space, use an electric cutting saw (saber saw, reciprocating
saw). In case of small-diameter reinforcements, use a chisel.

b. Cutting Steel Plate

There are a jig saw, a nibbler, and a band saw to cut steel plates, and each tool has
different efficiency, so select a suitable tool for the job site.

c. Cutting Metals
Because sparks are generated when you use a high-speed cutter with a grinding wheel,
you need to attach a chip saw designed for metals. The revolution speed must be
maintained under the value which is specified on the blade.

Figure 3.1 The highest revolution speed of a chip saw for metals (Example)

d. Cutting M&E Piping

For cutting M&E piping, it is best to remove it at a flange part or a screwed part. If that is
absolutely impossible, you can use a pipe cutting machine or an electric cutting saw.

e. Cutting Ducts
For cutting ducts, remove a duct at a flange part or use an electric cutting saw, a cutting
machine with a chip saw, or scissors designed for ducts.

5
3-2 Selection of Installation Methods

a. Installation of anchors
Anchors used for concrete skeleton are hole-in anchor bolts (metal extension anchor or
adhered anchor). Metal extension anchors are easy to use for installation of partition
walls or lightweight equipment, but it cannot be used for structurally important members
or members that generate vibrations. When you install anchors, pick one that fulfills the
purpose, the usage and the installation conditions as well as choose subcontractors
with well-established management system and experiences. With regard to the strength
of anchors, most of the maker catalogues shows breakdown value, so determine it
based on the standards of the allowable tensile force of anchor bolts.

b. Reinforcement Joints
If reinforcements are irregular shape and it is impossible to make lap joints, apply
mechanical joint. OS hoop clip is suitable for small-diameter (up to D16), and Tops Joint
method is suitable for large-diameter (D16~D51).

c. Metallic Fittings (Steel door, Shutter, Aluminum sash, etc.)

When you install a steel door in a concrete wall, you need to fix the anchor part with
mortar, or fix the disposable frame to the concrete with an anchor and then screw it or
tighten it with bolts. In case you install a steel door in a light gauge steel partition, attach
angle brackets to an opening reinforcing frame. When you install a shutter in steel frame
structure, tighten the base reinforcing frame with bolts. As for aluminum sash, you can
apply the same installation method as shutter installation method, or you can cover the
existing sash with new sash. In either case, you need to check the strength of the
fastener or the anchor bolt and determine the fixing method in the manufacturing stage
of the fittings.

d. Eave Soffit / Ceiling

According to the current standards of our company, ceiling works must be conducted
with fireless methods.
Also, have light gauge steel substrate members for ceiling manufactured (unitized) into
a transportable size at a factory wherever possible, and use bolts or screws for parts to
be installed on site. Even though it is difficult to unitize the members, there is a method
to use members which don’t require welding at all for installation.

e. Installation of Steel Stair Handrail

Fix mounting brackets for handrail lattices, 12Ø round pipes welded to a flat bar at a
factory, to cut stringers by bolts. Screw the handrail lattices.

f. Installation of M&E Piping

Unitize the piping into transportable size wherever possible, and joint them with flanges
or screws on site. In this case, consider special jointing (such as Straub Couplings) to
joint them with the main pipe.

6
g. Reinforcement of Ceiling Openings for M&E
As for an opening, the intersection of ceiling joist receivers and reinforcing channels
should be tightened by channel locks.

Joist (Double)
Joist (Single)
Channel Lock
Reinforcing
Channel Fix the intersection of ceiling joist
Reinforcing Channel [ 38 X 12 X 1.2 ] receivers and reinforcing channels
[ 38 X 12 X 1.2 ] with channel locks (example of
Joist Receiver Reinforcing Channel Nihon Kenko).
[ 38 X 12 X 1.2 ]

Joist Receiver

h. Assembly of Piping Pit

Drive anchors to the bottom of the pit, attach fully-threaded screw bolts, and then adjust
the height and apply mortar.

i. Installation of Anti-seismic Reinforcement Hardware

Carry out bolt joints as a general rule. However, if quality and performance are reviewed
in advance, you can use sandwich clamps or TIG Welding (Material 1-3).

3-3 Selection of Joints and Construction Methods for M&E Piping

In works that you choose “Fireless Construction Methods”, you are required to
adopt the following joints • methods.

a. General Piping
Select from Attachment “List of Fireless Piping Joint Method” (Material 1-2).

b. Refrigerant Piping
Select from Attachment “Characteristics of Mechanical Joint (Fireless Method) of
Copper pipe for Refrigeration” (Material 1-2).

c. Medical Gas Piping

Because it is provided that “brazing or welding must be applied”, you give up fireless
method but conduct hot work in accordance with hot work rules.

d. Others
Apply mechanical joints for piping as a whole. Even in case you carry out fireless
method, you might have no choice but to carry out hot work for branching parts from
existing piping welding. In this case, give up arc welding and consider TIG welding
which generate less sparks (Material 1-3).

7
 Material 1

Materials of Fireless Construction Methods

1-1 List of Construction Methods by Operation ······ 9

1-2 List of Tools • Construction Methods ··············· 13

1-3 Knowledge of TIG Welding ···························· 20

8
1-1 List of Construction Methods by Operation
※In terms of M&E piping, refer to “Fireless Piping Joint Methods” in Material 1-2.
Table 1-1 [Demolition Work]
(Grade A: Method which generate no fire, B: Method which generates a small amount of fire, C: Method which requires use of fire)
Operation Contents Grade Method Details
Demolition removal of the Manual operation with crowbar or hammer
Work interior
A Manually
etc.
Cutting of steel frame Removing bolts with tools (spanner,
of signage and A Manually
wrench, crowbar or hammer etc.)
advertising pillar or Cutting steel materials with an electric saw
sash A Saw cutting (saber saw, pipe saw, reciprocating saw,
etc.)
Cutting of steel
structure of Cutting steel materials by gas fusion
C Gas cutting
cutting
factory/plant
Cutting of slab for Cutting reinforcing bars less than 16Ø with
wastes to carry out A Re-bar cutter
oil pressure cutter
and reinforcing bar of Crushing machine Cutting reinforcing bars with cutter
wall A cutter attached to crushing machine
Cutting reinforcing bars by gas fusion
C Gas cutting
cutting
Cutting of M&E Removing bolts with tools (spanner,
piping or duct A Manually
wrench, crowbar or hammer etc.)
Cutting with an electric saw (saber saw,
A Saw cutting
pipe saw, reciprocating saw, etc.)

C Gas cutting Cutting by gas fusion cutting

Hazardous materials Separating joints with crowbar or wrench

(M&E equipment, Oil A Manually
etc.
tank, etc.) Removal to the Carried out by specialized disposal agency
A outside to demolish outside
Others
A Crushing Crushing by crushing machine

Cutting of reinforcing
bar
(RC structure, SRC
structure)
Cutting of steel frame
(S structure, SRC
structure)
Cutting machine Cutting with oil pressure cutter or saber
A manually saw etc.
Crushing machine Cutting reinforcing bars with cutter
A cutter attached to crushing machine
Cutting reinforcing bars by gas fusion
C Gas cutting
cutting
Removing bolts with spanner or wrench
A Manually
etc.
Cutting steel frames with an electric saw
A Saw cutting (saber saw, pipe saw, reciprocating saw,
etc.)
Crushing machine Cutting reinforcing bars with cutter
A cutter attached to crushing machine

C Gas cutting Cutting steel frames by gas fusion cutting

9
Table 1-2 [Building Frame Work]
Operation Contents Grade Method Details
Re-bar Joint of main A Mechanical joint Joint by screw, grout, or pressure bonding
Work reinforcing bar
Lap joint of main reinforcing bars less than
A Lap joint
D25
Gas pressure
C welding
Diffusion joint by oxygen-acetylene frame

C Enclosed welding CO2 semi-automatic welding

Cutting of reinforcing A Shear cutting Mechanical shearing with knife
bar
Cutting by chip saw attached to cutting
A Chip saw cutting
machine designed for chip saw
C Gas cutting Cutting by gas fusion cutting
Grinding of end face Use of end face Mechanically cut at a factory and cover
A protection material with protection such as fine press

B Disc sanding Sanding on site

Fixing of
reinforcement basket
A Binding Banding with iron wires or binding wires
2
Fixing by hand-arc welding or CO
C Spot welding
semi-automatic welding
Joint of Two-piece
clamp
A OS hoop clip Mechanical joint with sleeve and wedge

C Welding Flare welding of 2 re-bars for 10d long

Steel Joint of beam-column Joint with high-strength bolts in bracket

Frame
A High-strength bolt
form
Work
B TIG welding Welding butted flanges

C Welding Welding butted flanges

Joint of Joint with high-strength bolts except B.

column-column
A Bolt
BOX
Site welding of column flanges or skin
B TIG welding
plates of B. BOX
Site welding of column flanges or skin
C Welding
plates of B. BOX
Cutting of erection
piece or hanging piece C Gas cutting Cutting by gas fusion cutting

Cutting of temporary Removable unit

Hook a ladder to small pieces covered by
gangway ladder A ladder
fire resistive coating, Remove the ladder
after use
Gangway ladder
C attached to factory
Cutting by gas fusion cutting

Fixing of deck plate Shooting type

to beam
B riveting
Riveting with Hilti etc.

C Stud welding Fixing with stud

C Puddle welding Fixing by welding

Form Fixing of separator

Work
A Nailing, Screwing Fixing with nails or screw to floor forms

Attach subsidiary re-bars to slab

C Welding reinforcement or beam and apply welding

10
 Table 1-3 [Finishing Work]
Operation Contents Grade Method Details
Preparation Cutting of Cutting with oil pressure cutter, saber saw
A Manually
etc.
unnecessary re-bar
etc. C Gas cutting Cutting by gas fusion cutting
Waterproofing Asphalt A Asphalt cooling Spread asphalt sheet without heating
waterproofing
Blow torch can be used depending on type
B Sheet waterproofing
of sheet waterproofing
Pasting sheets while pouring hot melt
C Asphalt heating
asphalt
Stone Fixing of stone A Dry Fixing stones with anchors and fasteners

C Wet Welding re-bars for linking clamps

Block Joint of re-bar for A Mechanical Joint OS hoop clip, NMB Splice Sleeve etc.
blocks
C Welding Joint of re-bars by arc flare welding

Curtain Joint of fastener A Bolt Joint of fastener with high-strength bolts

Wall
B TIG welding Joint by TIG welding

C Welding Joint by arc welding

PC Cutting of hanging A Manually with saw Cutting with saber saw etc.
hardware
C Gas cutting Cutting by gas fusion cutting

ALC Fixing of hardware A Bolt Joint of hardware with high-strength bolts

B TIG welding Joint of hardware by TIG welding

C Welding Joint of hardware by arc welding

Steel Door Fixing to anchor Using anchor fastener and high-strength

A Bolt
bots together

C Welding Joint by welding to anchor with re-bars

Metal Joint of anchor or A Bolt Joint with bolts
joints
C Welding Joint by arc welding

Interior Adjustment of long vinyl Occasionally it is used to apply finishing

chloride sheet • C Blowtorch materials to the substrate during cold
baseboard season
Floor stone: Jet burner
(Floor) finish C Jet burner On-site work for repair
Reinforcement for
opening of lightweight
A Bolt, Screw Fixing with bolts or screws
(Wall) steel-frame partition
substrate C Welding Fixing by arc welding

Accessory ceiling Using specialized Joint with Channel intersection, Channel

A hardware lock, Channel joint of hanging wall
(Ceiling) base assembly,
Hanging wall C Welding Fixing by arc welding

Accessory ceiling Making a unit at factory and jointing with

A Unit screw
screws on site
base assembly
C Welding Fixing by arc welding
(Continued on next page)

11
 Table 1-3 [Finishing Work] (Continued from previous page)
Operation Contents Grade Method Details
Ceiling Bracing Using special parts
A Bolt Bracket to prevent horizontal motion
Bracket to prevent vertical motion

C Welding Fixing by arc welding

Eave soffit base According to the
A interior
Using hardware resistant to wind pressure
assembly
C Welding Fixing by arc welding
Eave soffit bracing C Welding Fixing by arc welding
Metallic ceiling
assembly C Welding Unitization can be adopted occasionally

Temporary Cutting of excess

Forging rebar
C Gas cutting Cutting by gas fusion cutting
Attaching lath substrate
hardware
Attaching miscellaneous
hardware C Welding Fixing by arc welding
Welding joint bar
Restoring dead hole
M&E Piping A Mechanical joint Basic joint method for extension work
Carried out in case there is no other choice
B TIG welding
in fireless area

C Arc welding Prohibited for repair work in principle

Table 1-4 [Temporary Work]

Operation Contents Grade Method Details
Temporary Joint • Cutting of Joint with high-strength bolt using fishplate,
A Bolt
Removing bolt with wrench for cutting
Work H-steel master pile
Joint with high-strength bolt, Cutting with
Joint • Cutting of A Chip saw chip saw (attach to high-speed cutting
machine for chip saw)
supporting post of
Welding • Joint by welding,
temporary bridge C Gas cutting Cutting by fusion cutting
Joint • Cutting of wale
bracket
A Vise joint Cutting by gas fusion cutting

Joint • Cutting of strut Pre-drilling a hole, Jointing with

corbel for support pile A Bolt
high-strength bolt
Joint • Cutting of
horizontal collar brace • Welding • Joint by welding as in the conventional
brace C Gas cutting manner, Cutting by fusion cutting
Thickening hole of Making a hole with a drill designed for
bolt joint A Reaming high-strength bolt joint (not by gas fusion
cutting)

C Gas cutting Thickening by gas fusion cutting

12
1-2 List of Tools • Construction Methods
List of cutting tools
Table 1-5 Reinforcing bar cutting machine
Electric oil pressure-style reinforcing bar Electric oil pressure-style reinforcing bar
cutting machine cutting machine

Product Name Electric oil pressure-style reinforcing rod Electric hydraulic rebar cutting machines bar
cutting machine bar cutter cutter

Maker Ogura Ogura

Application Cut of reinforcing bar Cut of reinforcing bar

Efficiency HBC-613 HBC-816 HBC-22 HBC-519 HBC-225 HBC-232

13Ø Cutting 16Ø Cutting 22Ø Cutting 19Ø Cutting 25Ø Cutting 32Ø Cutting
1.2 sec / piece 1.5 sec / piece 4.0 sec / piece 2.5 sec / piece 3.5 sec / piece 7.0 sec / piece

Main use To cut specified length To cut specified length

Table 1-6-a Cutting saw

Product Name Electric saber saw Compact • Reciprocating saw

Maker Hitachi Koki Makita

Application Cut of steel plate or pipe Cut of steel plate or pipe

Efficiency CR13VBY2 JR144D JR184D

Soft Steel Plate 19mm Copper Pipe 130mm Pipe 50mm Pipe 50mm

Main use To cut fixed object. For small gap. To cut fixed object. For small gap.

13
 Table 1-6-b Cutting saw

Product Name Tigair saw Pipe saw 165S

Maker Shingu Shoko Asada

Application Cut of steel plate or pipe Cut of pipe

6Ø Rebar 60mm Gas Pipe
Efficiency 15~200A Cast Iron Pipe for Gas
5 sec / piece 90 sec / piece

Main use Since cooling air is blown to saw blade, it is

To cut fixed object. For small gap.
useful in a hot work prohibited area.

Table 1-7 Jigsaw

Product Name Jigsaw Rechargeable Jigsaw

Maker Hitachi Koki Makita

Application Cut of steel plate Cut of steel plate

Efficiency CJ-90VST CJ-14DSL CJ-18DSL JV142D JV182D

8mm Cut 10mm Cut 10mm Cut 10mm Cut 10mm Cut

Main use To cut specified length To cut specified length

14
 Table 1-8 Nibbler

Product Name Nibbler Nibbler

Maker Makita Hitachi Koki

Application Cut of steel plate Cut of steel plate

Efficiency JN3200 CN32 CN45 CN60

3.2mm Cut 4.5mm Cut 6mm Cut
3.2mm Cut 1.3m / min
1.2m / min 1.8m / min 1.8m / min
Main use To dismantling steel plate To dismantling steel plate

Table 1-9 Bandsaw

Product Name Bandsaw Rotary Bandsaw

Maker Fuji Seito (Fuji Grinding Wheel MFG) Hitachi Koki

Application Cut of steel plate Cut of steel plate

Efficiency HRB-1140 • SC CB13FB

Round Pipe 120Ø, Square Pipe 120x115,
Round Pipe 123Ø, Square Pipe 105x105
Reinforcing Bar 40Ø
Main use To cut fixed object To cut specified length

15
 Table 1-10 High-speed cutting machine (

Product Name High-speed cutting machine Cutting machine

Maker Hitachi Koki Makita

Application Cut of metal Cut of metal

Efficiency CC12SF CC14SF CC16 2412NB 2414B 2416S

Pipe 102Ø, Pipe 102Ø, Pipe 140Ø, Pipe 115Ø, Pipe 115Ø, Pipe 115Ø,
Square Pipe
Square Pipe Square Pipe 215x100,
Square Pipe Square Pipe Square Pipe
80x100 130x115 Round rod 65Ø 119x119 122x122 120x120

Main use To cut specified length To cut specified length

Table 1-11 Disc Grinder (

Product Name Electric Disc Grinder Electric Disc Grinder

Maker Hitachi Koki Makita

Application Cut of reinforcing bar or anchor Cut of reinforcing bar or anchor

Efficiency PDA-100H G-10YH2 GA4041C GA403D GA404D

Round rod 10Ø Round rod 10Ø Round rod 10Ø Round rod 10Ø Round rod 10Ø

Main use To cut sash anchor To cut sash anchor

16
 Table 1-12 Pipe Cutting Machine

Product
REED Hinge Cutter
Name

Maker Omat

Application To cut pipe up to 360mm

Efficiency 8 inch pipe: 2min / piece

Main use To repair pipe

17
 List of Fireless Pipe Joint Method (Regular Pipe Joint) As of June 23, 2014

●: General Use, ○: Acceptable

Use

Cooling Water
Water Supply

Refrigeration
Ventilation ●

Fire Control

Cold Warm
Hot Water
Piping

Drainage
Supply

Steam
Joint Method Remark

Water
Gas
Material

Oil
Screw Joint ● ● ● ● ● ●

Flange Joint ○ ● ○ ● ● ○ ○

JPF MP 006. Taiyo Joint,

Housing Joint ○ ● ● ● Victaulic Joint, Top Joint etc.
Copper High-power Joint, LA Joint etc.
Type (Permission of Fire Service is
○ ● ○ ○ required for fire extinguishing
pipe.)
Mechanical Straub pipe coupling etc.
Joint ○ ○ ○ 50~300A, With slip-off
preventing mechanism
JPF MP 002. Flexible joint for
● drain copper pipe (MD joint)

Electric Brazing JIS H 3401 for small diameter

Joint
● ● (less than 40A)

Flare Joint ○
Copper
Lock Joint, Abacus Joint, RG
● Joint, Fireless Joint, AR Joint,
Mechanical Swagelok
Joint
○ ○ ○ ProPress

Process at factory,
Lap Joint ○ ○ ○ Install flange at important
spots
SAS 361: Victaulic Joint,
Stainless Housing Joint ● ○ ○ ○ ○ Top Joint, Taiyo Joint
Steel
SUS 322: Nice Joint,
Pipe
Mechanical Joint ○ ○ ○ ○ Z-LOK, SUS Fit, Abacus
Joint, BK Joint

Screw Joint ○ ○ Schedule Pipe

Mechanical Joint ●
Cast Iron
Pipe Large diameter (Tokyo
Housing Joint ○ Gas)

TS Joint ● ○ ● JIS K 6743

Hard chloride
vinyl pipe
Rubber Ring Joint ○ ●
Cross-linked JWWA B 116, JIS K 6779
Polyethylene Mechanical Joint Sleeve pipe header
pipe, One-Touch Joint ○ ○ method, Branch method,
Polybutene Electric Fusion Joint With error-proofing
pipe function

18
 Characteristics of Mechanical Joint (Fireless Method) of Copper Pipe for Refrigeration
List of joints which are validated and listed in the standards of construction management
As of June 23, 2014
Joint Lock Joint RG Joint Fireless Joint AR Joint Abacus CW, CZ
USCJ Copper Tube
Inaba Denki Sangyo, Kyokutoh Industry,
Maker Sandoh Sales,
JFE Pipe Fitting Nihon Denshi Gijutsu Higashio Mech
Toyofitting

Joint Form

Refrigeration All Types All Types All Types All Types R407c, R410A,
Type R32 (New
Joint Performance

refrigeration only)
Jointing Nut: SUS Brass Brass Brass Nut: Bronze
Material Body: Bronze Body: Brass
Sleeve: Brass
Jointing Sleeve Crimping Expandable Sleeve Expandable Nut Fastening
Method Crimping
Sealing Metal Gasket Metal Gasket Gasket
Method
Size Ø Applicable Size Applicable Size Applicable Size Applicable Size Applicable Size
6.35 ○ — — ○ ○
9.52 ○ ○ ○ ○ ○
12.70 ○ ○ ○ ○ ○
15.88 ○ ○ ○ ○ ○
19.05 ○ ○ ○ ○ ○
22.22 ○ ○ ○ ○ ○
25.40 ○ ○ ○ ○ ○
28.58 ○ ○ ○ ○ ○
Applicable Range

31.75 ○ ○ ○ ○ ○
34.92 ○ ○ ○ ○ —
38.10 ○ ○ ○ ○ ○
41.28 ○ — — — —
44.45 ○ — — — —
50.80 — — — — —
The forms are 22.22, 25.4 and
different between 28.58 have pipe
6.35~25.40 and elbow.
28.58~38.10.
Remark Regarding large
diameter, it Is
fastened with 4
bolts, so it is easier
to fasten.
Rotate
predetermined Fasten until the Fasten until the
Fastening
number of times nut touches the nut touches the Fastening torque Indicator
Control
Workability • Manageability

after manual body body

fastening
Marking position of
Item to check Gap dimension Gap dimension
gap dimension Marking and gap Marking position of
after between nut and between nut and
between nut and gauge gauge line
construction body body
body
Spanner and
Specialized Ready-made tube specialized Specialized Monkey wrench
Tool copper pipe expansion tool spanner extension oil-pressure flare suitable for width
locking tool (made by ESCO) handle for large tool across flats
diameter
Workshop Yes Yes Yes No Yes

19
1-3 Knowledge of TIG Welding

a. TIG Welding
TIG welding is short for Tungsten Inert Gas welding. It is a welding method to connect
work-pieces by melting the base metal and the welding rod with heat of arc which is
generated between the base metal and the tungsten electrode. Unlike coated arc welding
or CO2 semi-automatic welding, it doesn’t scatter sparks, so spark protection is not
necessary.

b. Characteristics of TIG Welding

Due to the use of tungsten electrode, highly stable arc can be obtained. In addition,
because inert gas such as Argon is used for shield, bead is smooth and glossy, and
welding defects such as blow holes or pits don’t occur easily.
A demerit is that it sometimes takes 5~10 times as long as semi-automatic welding due to
slow welding speed.

Photo 1.1 TIG welding application test

Tungsten Electrode

Welding Rod

Photo 1.2 How to hold electrode and welding rod Photo 1.3 Appearance of welding

20
 Material 2

Materials of Hot Work

2-1 Knowledge of Fire ········································ 22

2-2 Knowledge of Inflammable Material ················ 23

21
2-1 Knowledge of Fire

a. Fire generated by gas fusion cutting

The heating method by blowing oxidizing flame made by mixing oxygen and acetylene
is adopted for fusion cutting/welding of steel or pressure welding of reinforcing bars. The
flame temperature is extremely high and reaches over 3000℃.
Melting point of iron is 1530℃, and fire balls and sparks are very hot at 1500℃. The
melted iron gradually cools down, but even when it looks slightly red, its temperature is
close to 500℃, which is a temperature that timbers or papers easily catch fire.
Also, because air pressure blows away melted iron during fusion cutting, fire sparks
scatter farther, so it is necessary to provide full protection and full attention to sparks.

Figure Material 2.1 Scattering range of sparks during gas cutting

Building height (m)

Plate thickness 2.5mm

3
Oxygen pressure 5kg/cm

Scatter distance (m)

b. Fire generated by welding

Arc welding, which utilizes heat of arc generated between base metal and electrode, is
conducted with the amount of heat of about 6000℃. It’s not as many as gas fusion
cutting, but fire balls and sparks occur during welding, so we have to pay attention.
c. Fire generated by grinding wheel
Sparks which are generated by cutting steel using high-speed cutter • disc grinder with a
grinding wheel are fine particles, but due to the frictional heat, the temperature reaches
1500℃ and are as hot as the melting point of iron immediately after the sparks occur.
Therefore, they can become ignition sources depending on circumstances.
d. Fire generated by blowtorch
A blowtorch, which is used on a daily basis for installing vinyl chloride floor or processing
baseboards during interior works, is a tool to burn an object by vaporizing gasoline or
petroleum oil. The flame temperature reaches over 1500℃, and the vapor (vaporized
gas) of adhesives might catch fire.

22
2-2 Knowledge of Combustible Material

a. Flash ignition temperature

When a combustible material is heated and reaches to a certain temperature, it begins
to produce combustible gas. Consequently, if it gets a pilot flame such as flame, a spark
or hot object, it begins to burn, and the temperature at this stage is called flash ignition
temperature. In general, flash ignition temperature of wood is 260℃, paraffin 40℃,
Polyethylene/ Polystyrene/ Urethane foam/ vinyl chloride around 350℃.
However, paints, or greasy wastes or papers might catch fire even from a slightly
projecting part or a tip of fluff. In addition, chips, thin plates or fibrous pieces such as
dust, sawdust, charcoal waste, metal powder, can catch fire easily. Keep in mind that
there is a possible dust explosion by fine powder.

b. Foamed thermal insulation materials

Polystyrene foam (Styrofoam or Kane Light Foam etc.) or hard Urethane foam (Achilles
Katadan or Everlight foam etc.) are used as thermal insulation materials or materials for
notches of concrete forms. However, once it catches fire, it burns rapidly, which is called
deflagration, and produces a great deal of black smoke containing toxic gases.
Therefore, these materials have the potential to cause serious disasters.
In terms of in-site foaming two-liquid type hard urethane foam (Achilles Airlon, Air Light
Foam etc.), which produces thermal insulation layer by splaying at site, liquid B is highly
flammable, and it causes fire to spread instantly when it catches fire before dried.
Foamed thermal insulation used to be performed with Chlorofluorocarbon (CFC), but
due to recent increase in the use of non-chlorofluorocarbon, so the foamed thermal
insulation burns much more easily.

c. Hazardous substances
Many of adhesives for interior works or primers for waterproofing contain substances of
flammable solvent type, so if ventilation is not provided sufficiently, vapor catches fire of
blowtorch or sparks of grinder cutting, and a fire spreads instantly. With regard to these
highly flammable materials, you have to pay attention to the labels from the time of
delivery and fully consider the storage in addition to the usage.

23