Index

Index Pages
Chapter 1 Products
1.1 Products List
1.2 Products Details
Chapter 2 Features
2.1 Information
2.2 Scope of Application
2.3 Chemical Resistance
2.4 System Benefits
2.5 Marking
2.6 Raw Material
2.7 Structural Design
2.8 Important Design Principle
2.9 System Advantage
Chapter 3 Quality Assurance
3.1 System Standards
3.2 System Control
3.3 Internal Control
3.4 Testing and Accepting Incoming Goods
3.5 In-process Inspection
3.6 Process Control
3.7 Final Inspection
3.8 External Control
3.9 Quality Managment
Chapter 4 Installation
4.1 Instullation Introduction
4.2 Procedure
4.3 Installing of pipe Clamps
4.4 Laying piping in Walls
4.5 Special application
4.6 Use of short lengths of pipe
4.7 Trenching
4.8 Laying and Compaction
4.9 Completing site work
4.10 Initial Backfilling
4.11 Testing and Inspection
4.12 Completing Final Backfill
4.13 Pipe assembly
Chapter 5 Storage
5.1 Storage
5.2 Handling
5.3 Transportation

6
Our Services

7
 CHAPTER 1
Products

1.1 Products List

1.2 Products Details
 Notes

10
Dimension - Measurements - weight

11
1.1 Products List

12
 Drainage Solutions

1.2 Products Details Dn L (m) S (mm) Kg/ m

32 6 1.8 0.287
32 6 2.4 0.364
1ʺ” 6 1.8 0.297
1ʺ” 6 2.4 0.374
48 6 2.5 0.582
48 6 3.7 0.819
Export 50 6 2.5 0.618
Export 50 6 3.7 0.871
60 6 2.7 0.796
60 6 3.9 1.109
Export 63 6 1.9 0.608
Export 63 6 3 0.919
75 6 3 1.103
75 6 4 1.414
75 6 5 1.724
Export 90 6 3 1.333
110 6 2.8 1.542
110 6 3 1.623
110 6 4 2.111
110 6 5 2.567
160 6 4 3.130
160 6 5 3.909

Multi Layer Pipes Dn L S Kg/ m

75 6 3 1.067
75 6 4 1.381
110 6 3 1.61
110 6 4 2.114
110 6 5 2.575
160 6 4 3.034
160 6 5 3.733

β=45 degree
Dn L (m) H (mm) S (mm) Kg
32 49 22 4 0.032
1(Inch) 22.2 49 3.5 0.040
48 50 30 4 0.080
Export 50 52 33 4 0.070
60 61 35 4 0.110
Export 63 60 32 4 0.115
75 70 40 4 0.180
Export 90 81 42 4.5 0.235
110 93 45 5.5 0.390
160 140 70 6 0.921

13
 Drainage Solutions

β=87.5 degree
Dn L (mm) H (mm) S (mm) Kg
32 70 22 4 0.040
1(Inch) 43 21 3.5 0.050
48 72 30 4 0.110
Export 50 83 33 4 0.100
60 92 35 4 0.180
Export 63 105 32 4 0.143
75 109 40 4 0.290
Export 90 143.5 42 4.5 0.313
110 147 45 6 0.680
160 208 70 6 1.490

β=87.5 degree
Dn L H S Door Kg
60 91 85 4 75 0.242
75 109 40 4.5 75 0.355
110 145 45 6 110 0.675
160 209 70 6 110 1.490

β=87.5 degree
Dn L H S C Kg
32 58 22 3 95 0.070
1 (Inch) 58 22.1 3.5 95 0.080
48 71 30 4 127 0.150
Export 50 78 32 4 140 0.140
60 86 35 4 153 0.226
Export 63 71 32 4 139 0.200
75 100 40 4.5 189 0.365
Export 90 95 42 4.5 187.5 0.425
110 142 45 6 243 0.933
160 346 70 6 345 1.885

β=87.5 degree
D1 D2 H1 H2 C L S1 S2 Kg
75 60 40 34 167 96 4.5 4 0.300
110 50 46 33 200 103 6 5.5 0.670
110 60 45 36 180 105 6 4.5 0.632
110 75 45 40 196 121 6 4 0.680
160 110 71 45 288 169 6 6 1.420

14
 Drainage Solutions

β=45 degree
Dn L H S C Kg
32 47 21 3.5 90 0.072
1 (Inch) 48 22.65 3.5 95 0.080
48 86 30 4 142 0.170
Export 50 95 32 4 153 0.150
60 103 35 4 165 0.279
Export 63 112 33.6 4 177.5 0.275
75 128 40 4.5 202 0.414
Export 90 153 43.7 4.5 238 0.600
110 182 45 6 281 1.100
160 250 71 6 390 2.565

β=45 degree
D1 D2 H1 H2 C L S1 S2 Kg
Export 50 110 47 36 240 132 5.5 4 0.680
60 110 45 37 222 140 6 4 0.740
75 110 46 40 260 155 6 5 0.910
160 110 71 45 320 230 6 6 1.920

Cross 110/45º

Dn L H S C1 C2 Kg
110 145 51.3 6.5 281 367.8 1.560

Cross 87.5º
β=87.5 degree
Dn L H S C1 C2 Kg
75 104 46 4.5 189 207 0.500
110 145 45 6.5 293 245 1.326

Cross 87.5º/Reducer β=87.5 degree

β
S

D 1 D 2 L H S C1 C2 Kg
Export
β

110 50 107 47 5.5 200 214 0.720

D2

110 60 105 47 5.5 200 214.5 0.730

C1

110 75 114 47 5.5 200 255 0.875

H

D1

C2
L

3530910
15
 Drainage Solutions

Cross 45º/Reducer β=87.5 degree

C2

D1 S
D1 D2 L H S C1
Kg C2
Export 110 50 112 47 5.5 240 265 0.755

D
2
110 60 115.5 47 5.5 240 279 0.805
C1
110 75 126 47 5.5 240 312 0.890

H
L

3530910

º
β=87.5 degree
Dn L H S C Kg
60 86 36 145 4 0.301
75 100 40 189 4.5 0.441
110 141 45 242 6 0.920
160 203 71 345 6 2.000

β=45 degree
D1 D2 H1 H 2 C L S1 S2 Kg
75 60 40 35 65 96 4.5 4 0.365
110 60 45 35 185 107 6 5 0.710
110 75 45 36 199 122 6 6 0.745
160 110 71 45 288 214 6 6 1.505

Dn D1 D 2 L H S C Kg
Export 110 50 63 95.5 55 5 186.18 0.670
110 48 48 95.5 55 5 186.18 0.660
110 60 60 95.5 55 5 186.18 0.706

16
 Drainage Solutions

Dn L H S Kg
60 88 35 3 0.060
75 102 46 3 0.090
110 102 52 4 0.165

Elbow with inner thread 87.5º

Dn Thread H S C Kg
48 1.25” 30 4 59 0.120
48 1.5” 30 4 58 0.110
Export 50 1.25” 30 4 58 0.110
Export 50 1.5” 30 4 58 0.100

Floor Drain Plug

Dn L H S Kg
48 28 24 3 0.026
Export 50 28.5 25 3 0.030
60 29 25 3.5 0.035
63 35 30 5 0.04
75 69 65 4.5 0.05
110 111 40 3.5 0.140
160 43 38 5 0.23

17
 Drainage Solutions

Reducing Bush
Type D1 D2 H1 H2 L Kg
III 48 32 31 29 38 0.039
III 48 1” 31 29 38 0.035
III 50 48 33 28 43 0.010
III 60 48 36 30 45 0.060
III 75 48 38 33 48 0.125
Export II 75 50 40 36 50 0.110
II 75 60 42 38 52 0.110
Export II 110 50 46 38 58 0.250
II 110 60 50 38 61 0.260
I 110 75 50 38 61 0.266
I 110 114 36 34 40 0.060
I 160 110 65 56 77 0.533

Eccentric Reducer
D d H I L Kg
Export 90 50 43.5 30 117 0.158
Export 90 60 43.5 33 117 0.167
Export 90 63 43.5 33 117 0.170
Export 90 75 43.5 38 117 0.180
110 48 53 30 132 0.205
Export 110 50 54 38 132 0.235
3730500 110 60 54 38 132 0.240
Export 110 63 54 38 132 0.245
110 75 54 40 132 0.276
Export 110 90 54 46 132 0.278
160 110 67 48 167 0.500

Dn L H S Door Kg
Export 50 72 38 3.6 65 0.098
60 86 43 4 75 0.125
Export 63 65 40 3.6 75 0.113
75 100 50 4.5 75 0.145
Export 90 82 43 4.5 75 0.166
110 89 50 5 110 0.322
160 125 78 6 110 0.607

18
 Drainage Solutions

Dn L H S Kg
32 48 22 3 0.030
1 (Inch) 48 22 3 0.028
48 65 31 4 0.060
Export 50 72 36 4 0.050
60 80 40 4 0.090
Export 63 66.5 32 4 0.080
75 94 45 4.5 0.150
Export 90 87 42 4.5 0.166
110 109 52 5.5 0.330
160 145.5 70 6 0.650

Socket with Inner Thread

Dn Thread L H Kg
48 1.5” 100 85 0.076

35309630

Dn L H S C Kg
50 100 30 3 170 0.165
75 150 39 4.3 240 0.467
110 45 45 6 305 1.218

Repairing Socket With Expansion Joint

Dn H S Kg
75 82 4 0.335
110 142 5 0.685
160 175 5 0.705

19
 Drainage Solutions

Repairing Socket
Dn L S Kg
160 145.5 5 0.645

37309991

Dn L H S Kg
48 91 32 4 0.105
50 91 32 3 0.090
60 109 36 4 0.160
75 125 40 4 0.220
110 114 50 6 0.683

Dn L H S Door Kg
110 114 50 5.5 100 0.685

Short Cross 87.5º β=87.5 degree

Dn L H S C1Kg C2
60 71 35 4.2 139 142 0.250
63 71 35 2.7 139 142 0.195
90 95 42 4.5 187 190 0.500
110 112 48 5.7 216 225 0.870
5309 160 158 68 6 305 316 1.860

20
 Drainage Solutions

Short Cross 87.5º / Reducer β=87.5 degree

D1 D2 L H S C1 C2 Kg
90 63 94.5 42 2.7 187 189 0.415
110 48 104 48 3.7 216 208 0.675
110 50 103 48 3.6 216 207 0.670
110 60 112 48 4.2 216 225 0.695
5309 110 63 112 48 3.9 216 225 0.690
110 75 112.5 48 4.2 216 225 0.690
110 90 113 48 4.9 216 226 0.710

Eccentric Reducer with gasket

D d H I L Kg
63 50 44 46 115 0.095
60 50 44 46 112 0.09

7305

Short Tee 87.5°

Dn L H S C Kg
110 112 48 5.7 216 0.76

5308

Short Tee 87.5°/Reducer

Dn1 Dn2 H1 H2 C L S1 S2 Kg
110 48 48 32 216 104 5.7 3.7 0.675
110 50 48 30 216 103 5.7 3.6 0.67
110 60 48 36 216 112 5.7 4.2 0.695
110 63 48 36 216 112 5.7 3.9 0.69
110 75 48 40 216 112.5 5.7 4.2 0.69
5308 110 90 48 42 216 113 5.7 4.5 0.71

21
 Drainage Solutions

L D1 D2 S Kg
30 75 85 4 0.090
30 110 122.5 4 0.180
38 161 180 7.5 0.323

Pipe Plug
Dn H S Kg
1" 21.5 2.3 0.013
32 21.5 2.3 0.01
50 26 2.3 0.022
75 35.5 3 0.05
160 51.5 3 0.195
5309

L1 L2 L3 D D1 D2 D3 X S Kg
84 145 115 48 87 77 40 115 7 0.230

Measurements in mm.
D in D out C1 C2 L1 L2 S2 Kg
48 60 117 110 200 175 5 0.370

22
 Drainage Solutions

Drain 8.8 Cm
D in D out C1 C2 L1 S Kg
75 60 111.5 108 220 4.5 0.475

37301002

D in D out C1 C2 L1 L2 S2 Kg
48 75 125 110 193 170 4 0.450
48 60 125 110 180 170 4 0.425
60 75 125 110 193 180 4 0.470
60 60 125 110 193 180 4 0.465
Export 50 75 125 110 220 180 4 0.430
48/60 75 130 120 197 185 4 0.570
50 60 125 110 195 180 4 0.400
110 110 201 200 280 280 5 1.500
110 160 170 160 240 240 5 0.800

D H L S Kg
96 72 76 3 0.080

Floor Drain with Water Preventer

D in D out C1 C2 L1 L2 S2 Kg
48 75 125 110 193 170 4 0.589
48 60 125 110 180 170 4 0.662
60 75 125 110 193 180 4 0.630
60 60 125 110 193 180 4 0.562
Export 50 75 125 110 195 180 4 0.572
37301002

23
 Drainage Solutions

Floor Drain with oder trap

D in D out C1 C2 L1 L2 S Kg
48 60 125 110 191 60 4 0.54
48 75 125 110 196 180 4 0.575
60 60 125 110 195 170 4 0.570
60 75 125 110 200 180 4 0.700
63 90 125 110 211 180 3 0.545
7301

Dn H L C S Kg
110 17 93 150 4 0.270
125 17 99 200 4 0.390

37303000

L A B Kg
Closed 192 56 182 0.280
Open 192 56 182 0.270

Dn L X Y M N S Kg
75 154 164 157 45 194 4 0.630
110 154 164 157 45 194 4 0.530

24
 Dimension - Measurements - weight

Side Cross
Dn1 / Dn2 β C1 C2 C3 S H L Kg
110 87.5° 216 188 188 5.6 45 127 0.935

Pipe Lubricant
Code Description Kg Pieces/Box
377020020 SH Pipe lubricant for plastic pipes 150 ml Tube 50

377020021 SH Pipe lubricant for plastic pipes 250 ml Tube 50

377020022 SH Pipe lubricant for plastic pipes 500 ml Tube 24

A pipe jointing compound based on vegetable soap lubricants applicable for all
drinkable water pipes and drainage solutions to permit easy and speedy fixing of
sealing joints on nearly all pipe materials.

Flexible Hoses

• Braiding Made Of stainless steel 304.

• Inner Hose made of high-quality EPDM rubber.
• The inner diameter is 8 mm and the outer diameter is 12 mm.
• Temperature service up to 90°.
• Stand up to 10 bar working pressure.
• Sizes are 30 cm, 40 cm, 50 cm, 60 cm.
• According to BS EN 13618:2011.

25
 Drainage Solutions

26
Drainage Solutions

27
 Drainage Solutions

Inspection Chamber Ø600mm

■ Smart Home Polypropylene inspection

chamber constructed with modular
structure for underground installation
with internal diameter of 548mm
and 870mm adjustable height. (See
drawings).
■ Excellent resistance for aggressive
waste water.
■ Three Ø160mm socket-pipe Inlets and
one Ø160mm Pipe outlet.
■ Coming with 410mm height PP vertical
extension section contains 5 steps allow
height extending or trimming by 69mm
(cutting lines are marked by CUT HERE).
■ Modules are assembled to each other›s
and sealed by 13mm thick O-ring made
of natural rubber suitable for drainage
applications.
■ Available with 285mm optional vertical
extension having 2 extra Ø110mm inlet
PP socket-pipes installed at any desired
depth above the main body.
■ 60cm x 60cm Strong PP cover able to
withstand up to 2 Tons of static load,
and attached with stainless steel loose
handles for easier removing.
■ Having a free volume flow rate of 2500
liter/min.

28
 Drainage Solutions

Drainage Water Channel

• Smart Home New reinforced

Polypropylene drainage water
channel constructed for
underground installation with
20cm width, 20cm depth and
1m Length.
• Excellent resistance for
aggressive waste water.
• Four optional lateral pipes
outlets, Ø110mm at each side,
and Ø50mm at each side.
• One optional bottom outlet
Ø75mm.
• Designed for easily attachment
at both ends for extending
purposes either in longitudinal
or transversal directions.
• Every unit contains 5 optional
cutting steps allow length
trimming by 10cm for each
step (cutting lines are marked
by CUT HERE).
• Strong PP cover able to
withstand up to 2 Tons of
static load.
• Designed to be anchored to
set the location before final
fixation.
• Having a free volume flow rate
up to 500 liter/min.

29
 Drainage Solutions

30
Accessories

Angle valve ½” X ½” Washing machine valve ¾” X ½”

PVC pipes clamps

Measurements in mm.
Hexagon Hex Head Fisher
Pipe Size Thickness Width Fisher
Welding nut Bolt Bolt
60 2.5 20 M8 6*30 8 * 80 S10
75 2.5 30 M10 6*30 10 * 100 S12
110 3 30 M10 6*30 10 * 100 S12

31
 PVC Adhesives and water proofing solutions

Bitumen Emulsion (BITU COAT)

BITU COAT is waterproofing based on emulsion bitumen.

It is designed to be used on walls and floors to prevent
water ingress and dampness from the ground. It will
provide a waterproof membrane on concrete and brick
foundations, retaining walls and bridge abutments. It
protects concrete structures against attack by sulphates
present in soils.
Packing
Bitu Coat is supplied in 3 kg and 12 kg packs.

PVC Solvent Cement

The best solvent cement solution

for UPVC and CPVC pipes (Hot)

The best solvent cement solution

for Grey UPVC pressure pipes

The best solvent cement solution

for UPVC pipes (Cold)

The best Cleaner for all pipes

32
Notes

33
 CHAPTER 2
Features

2.1 Products Information

2.2 Scope of Application
2.3 Chemical Resistance
2.4 System Benefits
2.5 Marking
2.6 Raw Material
2.7 Structural Design
2.8 Important Design Principle
2.9 System Advantage
 Features

2. Features

2.1 Products Information

Smart Home PVC-U underground and sewage piping system is one of the most
comprehensive on the market with a full range from 32mm to 160mm in diameter.
Smart Home was a pioneer in the development and marketing of PVC-U systems for
this application and is well known for its excellent product quality.
The advantages of the SMART HOME pipes are well accepted, they are lightweight,
resistant to a wide variety of chemicals, do not support combustion, they are not
subject to electrolytic corrosion. The fittings are designed with a high impact
strength, which helps prevent damage during handling and installation. All parts
assemble easily using solvent cement to accommodate thermal or ground movement.
Pipes and fittings are manufactured according to ES 1717,ISO 4435, DIN 19534,
DIN EN 1401, DIN EN 1329, DIN 80618062/, ISO 3633, ASTM D3311, and ASTM
D2665 standards suitable for use below ground for general municipal drainage.
All products comply with or exceed relevant International standards to ensure
reliability and long-lasting service.

Smart Home System Information

Material Poly Vinyl Chloride – Un-Plasticized

Size 32mm– 160 mm
• Waste water pipes in buildings and
laid above and underground inside and
Area of application outside the building structure
• Water Management systems
• Ducting systems
Jointing PVC Solvent Cement
Pipe:- White by two orange stripes
Color
Fittings:- White
Installation temperature Up to 60°C
Installation location Indoors ,Outdoors and below ground

2.2 Scope of Application

Smart Home pipes and fittings are mainly used for Non- pressure drainage lines
resistant to hot water for domestic and industrial.
• In single and multiple family house construction
• In apartment construction

36
 Features

• In renovation construction
• In industrial plants
• In large scale kitchens and laundries
• In schools, universities
• In hotels, convalescent homes
• In infirmaries and many others
Inside these buildings the Smart Home system can be used for:
• Individual and collective lines
• Downpipes
• Ventilation pipes
• Interior rain water pipes
• Pipes for central dust extraction systems
• Pipes, fittings and sealing elements are also suitable for the transportation of
chemically aggressive
• Electric and telecommunication cables ducts
• Air conditioning drainage system

2.4 System Benefits

Dimensions and performance meet the requirement of Egypt, Germany, America
andInternational standards.

Low Friction Loss

The smooth interior surfaces of Smart Home system assure low friction loss and high
flow rate. Additionally, since PVC-U resist rusting, pitting, scaling and corrosion, the
high flow rate can be maintained for the life of the piping system.

Easy Installation
Smart Home system is light in weight (approximately one-half the weight of
aluminum and one-sixth the weight of steel) reducing transportation, handling, and
installation cost. No special tools are required for cutting. These materials can be
installed using the solvent cement joining technique.

Cost Effective

Longer pipe lengths, flexibility and the use of narrow trench widths significantly
reduce installation costs, the major portion of the total in-site costs.

37
 Features

38
Features

39
 Keywords

40
Features

41
 Features

42
Features

43
 Features

44
Features

45
 • Pipes for central dust extraction systems
• Pipes, fittings and sealing elements are also suitable for the transportation of
chemically aggressive Features
• Electric and telecommunication cables ducts
• Air conditioning drainage system

2.4 System Benefits

Dimensions and performance meet the requirement of Egypt, Germany, America
andInternational standards.

Low Friction Loss

The smooth interior surfaces of Smart Home system assure low friction loss and high
flow rate. Additionally, since PVC-U resist rusting, pitting, scaling and corrosion, the
high flow rate can be maintained for the life of the piping system.

Easy Installation
Smart Home system is light in weight (approximately one-half the weight of
aluminum and one-sixth the weight of steel) reducing transportation, handling, and
installation cost. No special tools are required for cutting. These materials can be
installed using the solvent cement joining technique.

Cost Effective

Longer pipe lengths, flexibility and the use of narrow trench widths significantly
reduce installation costs, the major portion of the total in-site costs.

Non-Flammability

Smart Home system does not support combustion.

Non-conductivity

Smart Home system is a non-conductor of electricity, and is therefore not subject to

galvanic or electrolytic action.

Effect on elevated temperatures

Smart Home system is capable of handling typical waste water discharge

temperatures up to approximately 60°C and is therefore satisfactory for use in soil
and waste systems where continuous full bore discharges of effluent are unlikely to
exceed this figure.

Effect of low temperature

The impact strength of Smart Home pipe and fittings decreases with reduction in
temperature therefore increased care should be exercised if installations are carried in
low temperature conditions.

Corrosion resistant

46The inert nature of Smart Home PVC-U pipe provides complete corrosion resistance,
and renders wrapping, coating and lining unnecessary. This inert nature ensures that
Effect of low temperature
Features
The impact strength of Smart Home pipe and fittings decreases with reduction in
temperature therefore increased care should be exercised if installations are carried in
low temperature conditions.

Corrosion resistant

The inert nature of Smart Home PVC-U pipe provides complete corrosion resistance,
and renders wrapping, coating and lining unnecessary. This inert nature ensures that
PVC-U sewer and drainage pipes have a long operational life.

Leakage elimination

Groundwater infiltration due to broken and cracked elements in the system, joint
opening and ground movement are eliminated by the precision joints, flexible pipe
barrel and sealed access points provided by the PVC-U sewer pipe and fittings
system. Longer pipe lengths means fewer joints, further reducing possible sources of
leaks, which research has shown to be directly proportional to the number of joints.

The solvent cement joint provided with the system eliminates the contamination of
the groundwater and surface waters by sewer effluent with the resulting health
hazards, visual pollution and public concern.

Low Thermal Conductivity

Smart Home pipe have a much lower thermal conductivity factor than metal pipe.
Therefore, fluids being piped maintain a more constant temperature. In many cases,
pipe insulation is not required.

Expansion and contraction

Piping which is being laid in hot weather will be in an expanded condition and will
subsequently contract on cooling. It must be remembered that every 6m length of
PVC-U pipe will expand or contract approximately 5mm for every 10ºC rise or fall in
temperature. Precautions against damage due to contraction can be taken by using
SMART HOME expansion joints.

Beneficial to Public Health

Smart Home system is clean and safe, it is so safe that it is used for intravenous
medical tubing, and it is the pipe of choice for ecologically sensitive environments
like salt water aquariums

Best Choice for the Environment

Smart Home system is one of the world’s most sustainable products, making it ideal
for long-term use in underground infrastructure. It requires less energy and fewer
resources to manufacture than old-technology materials, and its production creates
virtually no waste.

Moreover, it is produced with sustainable and abundant resources: chlorine, which is47
derived from salt, and domestically produced natural gas, which helps reduce
 Best Choice for the Environment

Smart Home system is one of the world’s most sustainable products, Features
making it ideal
for long-term use in underground infrastructure. It requires less energy and fewer
resources to manufacture than old-technology materials, and its production creates
virtually no waste.

Moreover, it is produced with sustainable and abundant resources: chlorine, which is

derived from salt, and domestically produced natural gas, which helps reduce
consumption of imported oil.

Clean and Safe Manufacturing

PVC-U pipe manufacturing is extremely efficient, with virtually100 % of the PVC

compound being used. It takes four times less energy to make than concrete pipe, and
half that used for iron pipe.

Non Toxicity

PVC products are completely non-toxic in normal use, are suitable for use with food.
It is a safe material and a socially valuable resource that has been used for more than
half a century. It meets all international standards for safety and health for both the
products and applications for which it is used.

2.5 Marking
Marking of Pipe

1. The Brand
2. Material Type (PVC-U)
3. The Number of Standards specification ex: - ES 1717.
4. Drain, Waste and Vent (DWV) system.
5. Dimension of the pipe (OD*Thickness).
6. The Extrusion Line and Shift No.
7. The Date and Time of production
8. Made in Egypt with superior Germany quality by Egyptian German Industrial
Corporate S.A.E (EGIC)

Marking of Fittings

1. The Brand
2. Degree of the angel.
3. The Number of Cavity.
4. The month and Year of Production.

48
 Features

Material and Technical Specifications

2.6 Raw Material

Poly Vinyl Chloride (PVC)

49
 Features

Technical Specifications

Characteristic Unit Values

Physical Properties
Density kg/cm3 1.38
Water Absorption mg/cm2 0.71
Mechanical Properties
Modulus Of Elasticity N/mm2 3000
Compressive Strength N/mm2 66
Flexural Strength N/mm2 95
Tensile Strength N/mm2 50
Impact Strength (Charpy) No Break
Shore Hardness R 115
Thermal Properties
Vicat Softening Temperature ºC >82
Max. Operating Temperature ºC 60
Longitudinal Reversion <2%
Specific Heat KJ/Kg.K
Coefficient of Thermal Expansion m/m.K 8 x 10^- 5
Thermal Conductivity W/m.K 0.16
Electrical Properties
Volume Resistively Ώ.cm >1014
Surface Resistance Ώ 2.4*1012
Dielectric Strength Kv/mm >40

50
 Features

System Design

2.7 Structural Design

Smart Home range of PVC pipes 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.
2.8 Important Design Principle
Pipe Sizes
The correct sized pipes should be used throughout the installation to ensure an
efficient flow through the drainage system.
Gradient
Access
Access to a drainage system should be included wherever there is a change in
direction.
Venting
All drainage systems require a vent to allow fresh air to be taken into the system to
ensure a smooth running to the discharge.
Expansion
It is important to allow for expansion in all plastic drainage system. Solvent weld
systems should use expansion joints where required.
Traps
Each appliance (Shower, Basin etc.) should have its own trap.
Connection to a floor gully provides an additional trap to prevent foul odors escaping
into living space areas.

2.9 System Advantage

Smart Home systems offer integrated solutions. This enables specifies and installers to
assemble complete drainage, plumbing systems from a single source, with complete
confidence in compatibility and performance. All systems are backed by comprehensive
technical support and a nationwide distribution network to ensure availability when and
where required.

51
 Features

Smart Home characterized by the following features:-

• High quality product
• Excellent fluid flow characteristics
• Immunity to all types of corrosion
• Good mechanical strength
• High ring stiffness
• Fast and easy installation
• Light weight, ease of installation, ease of maintenance
• Good electrical insulation properties

4.1 Introduction
One of the most significant advantages of Smart Home PVC-U pipe system is its
light weight. This means that the pipe can be easily handled and longer lengths can be
installed without sophisticated lifting machinery and with minimum in-trench labor.

Long pipe lengths increase the speed with which a system can be installed, and also
mean that pipelines are less susceptible to misalignment and consequent blockage
following possible ground movement, than those made up of short pipe lengths.

All pipework must be supported whether vertical or horizontal

Pipe brackets must be used to anchor expansion joints. Intermediate support must
also be provided to steady pipework between points

Horizontal pipework requires more frequent support than vertical pipework

Pipework should always be supported close to any change of directions (e.g. Bends
or branches)

4.3 Installing of pipe clamps

Smart Home waste water piping systems are always to be laid so that they are free of
tension and changes in length are not inhibited.

Generally pipe clamps with inserting tapes are to be used for fixing the pipes. These
tapes have to be adjusted to fit the outer diameter of the pipe and must fully surround
the pipe. Should no insertion tape be used, the interior edges of the clamps must be
rounded and the inner surfaces must be smooth.

52
Notes

53
 CHAPTER 3
Quality
Assurance

3.1 System Standards

3.2 System Control
3.3 Internal Control
3.4 Testing and Accepting Incoming Goods
3.5 In-process Inspection
3.6 Process Control
3.7 Final Inspection
3.8 External Control
3.9 Quality Managment
 Quality Assurance

Quality Assurance

3.1 System Standards

Smart Home manufacturing according to the following standards:

ES 17172008/
Pipe and Fittings made of Unplasticized Poly (Vinyle Chloride) (PVC-U) for
underground drainage and sewage system

ES 848-12008/
Pipe and Fittings made of Unplasticized Poly (Vinyle Chloride) (PVC-U) for water
supply system

DIN 80618062/
Unplasticized Poly (Vinyle Chloride) (PVC-U) Pipes

DIN EN-1401
Plastic piping system for non-pressure underground drainage and
sewerageUnplasticized Poly Vinyle Chloride (PVC-U)

DIN 19534
Plastic piping system for non-pressure underground drainage and
sewerageUnplasticized Poly Vinyle Chloride (PVC-U)

ISO 3633
Plastics piping systems for soil and waste discharge (low and high temperature)
inside buildings -- Unplasticized Poly (vinyl chloride) (PVC-U)

ASTM D 2665
Poly(Vinyl Chloride) (PVC) Plastic Drain, Waste, and Vent Pipe and Fittings

ASTM D 3311
Standard Specification forDrain, Waste, and Vent (DWV) Plastic Fittings

DIN EN 1329
Poly(Vinyl Chloride) (PVC) Plastic Piping System for soil and waste discharge (low
and high temperature within the building structure

56
 Quality Assurance

ISO 4435
Plastics piping systems for non-pressure underground drainage and sewerage –
Unplasticized poly (vinyl chloride) (PVC-U)

ISO 9969
Determination of ring stiffness for Thermoplastics pipes

DIN 4102
Fire behavior of building materials and building components.
3.2 System Control
The production of Smart Home superior high quality piping system calls for the
regulation and control of all areas of the operations. All results are documented and
archived:
- Testing and accepting incoming goods.
- Process Control.
- In- process inspection.
- Final inspection tests.
Regulation for the quality control of Smart Home drainage system include all above
standards that feature the minimum requirements for internal control.
Conformance to the superior quality standards is verified through independent
authorities, by internal audits and Laboratory tests. Smart Home quality standards are
controlled by Egypt regulations.

EGIC is a highly qualified and experienced manufacturer in extrusion and injection

molding.
EGIC is also the market leader and pioneer in the manufacturing of PVC-U drainage
system in Egypt.
This is reflected in our internal quality standards and procedures, which are
illustrated by the constant quality of our products.
3.3 Internal Control
A team of highly trained and qualified QC engineers, equipped with a state of art
laboratory, ensure that all test are carried out in compliance with our quality control
policies, which includes:
- Testing all Raw Materials.
- Measuring and inspecting our production equipment.
- Auditing our production procedures.
- A final inspection for the quality of our finished products.
- All internal quality audits are documented and archived in accordance with the
highest standard quality control; polices.

57
 Quality Assurance

EGIC laboratory
EGIC laboratory serves one of the most important functions in our production and
process control. A significant portion of the EGIC regulations pertain to the quality
control laboratory and product testing to be able producing the highest quality
products.

EGI laboratory have the most advanced equipment made in Germany with high
technology.

EGIC Laboratory Equipment:-

• Universal Testing Machine - Tensile Tester

• Hydrostatic Pressure Tester
• Shore Hardness Tester - Durometer
• Charpy / Izod Pendulum Impact Tester
• Gardner Impact Tester
• Falling Dart Impact Tester
• Full Notch Creep Tester
• Melt Flow Tester - Melt Flow Indexer - MFI
• Specific Gravity Tester - Densimeter
• Sample Specimen Preparation Equipment
• Milling Machine
• Thermo bath
• Thermo oven
• Laboratory Granulator
• Apparent / Bulk Density Tester
• Laboratory Mixer
• Laboratory Roll Mill
• Platen press
• HDT/VICAT Heat Deflection Testers
• Limiting Oxygen Index Chamber
• Brittleness Point Temperature Tester
• Moisture content apparatus
• Differential Scanning Calorimeter
• Sieve Analysis Tester

58
 Quality Assurance

• Humidity Tester
• Viscometer Tester
• Drying time apparatus
• Bending resistanceTester
• Rotary Microtome
• Pigment dispersionTester
• Microscope Axio Imager

3.4 Testing and Accepting Incoming Goods

All incoming goods are carefully inspected, to insure that the raw material
conformsto the set requirements. Goods that haven’t been tested don’t release for
production.
The incoming raw materials are tested according to ISO 1133.
3.5 In-Process Inspection
The quality plan requires that all inspections are carried out at the beginning as well
as during production. As production starts all relevant data are checked by the quality
assurance department.
Pre-production samples are testes by the laboratory engineers and technicians for the
following test:-

- Surface finish
- Dimensional accuracy
- Check Marking
- Date for extrusion and injection molding machines
- The product is only released if optimal tests are achieved

3.6 Process Control

We have an extensive quality control process in the field of extrusion, which uses
Ultrasonic measurements and data recording. This enables constant observation and
control of production. Ultrasonic automatically measure and report any deviations in
tolerance of the cutting device on the extrusion machine, thus isolating any
substandard products. This ensures that only perfect quality products are packed and
stored. All data received during production is studied and analyzed, in details.

59
 Quality Assurance

3.7 Final Inspection

QC requires that inspections and tests are carried out on all finished products. The
results are all documented. Finished products are only released to storage when all
tests and inspections have conformed to authorized procedures and specifications.
The final tests include a time lapse procedure. This measures the usability of the
products in their fields of application, as well as removing production weaknesses.
These inspections are the method for quality assurance during production and for
design tests. The results document the system quality and serve to optimize the
manufacturing process.

The final inspection covers the following main tests:-

Visual control
Aspect, roughness, opacity, conformity of color, chamfer, porosity, detect any trace
of burning, clean cut, no irregularities, ... all those controls are performed without
magnification, they allow to detect any eventual trouble in the manufacturing process
at the closest points of the extrusion lines

Dimensional control
Outside diameter, wall thickness (8 points), overall length, (length, groove, etc...), out
of roundness, mean outside diameter, measured with the adequate calibrated
measuring instruments. This test carried out according to ES 1717 standard.

Impact resistance:
A calibrated weight from a specified height falls on the product a number of times,
without any friction: passing the test demonstrates the impact resistance of the PVC
product according to ES 1717 standard.

Methylene Chloride
Product is tested by immersion in methylene chloride, a very corrosive solvent, at
23°C during 20 minutes. Product tested should show no attack at any point of the
pipe (internal, external, through the wall), proving that the fusion temperature has
been reached. If this point is not reached, the filler used in the formulation for
lubrication flows between the molecules to the surface, and proves that the
polymerization is not complete, and thus: that the properties of PVC are not met. This
ageing test reveals the imperfection of the product. A product is in compliance if the
mix of temperature-pressure-speed is well tuned in order to reach the fusion point
(very variable according to product, conditions, material, ...) but still not reaching the
degradation stage (burning); because the measurement of the degree of fusion is very

60
 Quality Assurance

costly and almost impossible to obtain with the number of variables, the solvent test
is a substitution considered as very accurate.This test carried out according to ES
1717 standard.

Longitudinal reversion:
A sample of the product is immersed in an oven during 30 minutes at 150 °C: all
tensions are released at this temperature considered as the beginning of fusion. The
product is then cooled at ambient temperature, and the deformation measured
(shrinkage acceptable if smaller than 5%. This test helps to identify some processing
abnormalities that might affect the pipe dimensions at long term, by evaluating
theeffect of heating on the pipe.This test carried out according to EN 743 standard.

Vicat softening point

A sample is immersed in oil and the temperature is elevated from ambient until it
reaches its softening point (minimum acceptable is 79°C). Softening point is reached
when a calibrated needle under a weight of 5kg penetrates up to 1mm into the
product. Higher point demonstrates the ability of the pipe to withstand
hightemperature . This test carried out according to EN 727 standard.

Specific gravity
It allows verifying that the PVC content complies with the requirements of the DIN
1401 standard (at least 80% by mass for pipe, and more than 85% for fittings), failing
which the pipe will not withstand long term operation (50 years). This test allows
demonstrating that the filler content does not exceed a reasonable percentage of the
mixture.

Internal Pressure
Internal pressure resistance test for pipeand fittings carried out according to ES 1717
and EN 921. Pipes and fittings didn’t burst or leak during the stressing period.Time
and temperature values must be as in standards.

Marking
Should be in compliance with the requirements of ES 1717standard as well as those
of the brand, should include all useful data allowing the traceability of the
manufacturing process and all the steps of the quality control.

61
 Quality Assurance

3.8 External Control

External supervision consists of measuring the fixed scope at fixed intervals. The
respective supervising institutions appoint the appropriate authorized organization to
carry out external supervision. Inspection includes:

- External tests of products

- Internal audit of Smart Home quality assurance system and test procedures

- Calibration of test equipment

- Hygienic and toxicity tests

3.9 Quality management

Smart Home is developed and manufactured within an ISO 9001 Quality assurance
system. It emphasizes on quality care and continuous improvements in customer
satisfaction.

Furthermore Smart Home has integrated the ISO 14001 environmental management
system to control and improve our overall environmental performance.

Smart Home also integrated OHSAS 18001, Occupational Health and Safety
Management systems.

7. Chemical resistance
Same at pages 29 till 36

62
Notes

63
 Dimension - Measurements - weight

64
Dimension - Measurements - weight

CHAPTER 4
Installation

4.1 Instullation Introduction

4.2 Procedure
4.3 Installing of pipe Clamps
4.4 Laying piping in Walls
4.5 Special application
4.6 Use of short lengths of pipe
4.7 Trenching
4.8 Laying and Compaction
4.9 Completing site work
4.10 Initial Backfilling
4.11 Testing and Inspection
4.12 Completing Final Backfill
4.13 Pipe assembly

65
 • Good mechanical strength
• High ring stiffness
• Fast and easy installation Installation
• Light weight, ease of installation, ease of maintenance
• Good electrical insulation properties

4.1 Introduction
One of the most significant advantages of Smart Home PVC-U pipe system is its
light weight. This means that the pipe can be easily handled and longer lengths can be
installed without sophisticated lifting machinery and with minimum in-trench labor.

Long pipe lengths increase the speed with which a system can be installed, and also
mean that pipelines are less susceptible to misalignment and consequent blockage
following possible ground movement, than those made up of short pipe lengths.

All pipework must be supported whether vertical or horizontal

Pipe brackets must be used to anchor expansion joints. Intermediate support must
also be provided to steady pipework between points

Horizontal pipework requires more frequent support than vertical pipework

Pipework should always be supported close to any change of directions (e.g. Bends
or branches)

4.3 Installing of pipe clamps

Smart Home waste water piping systems are always to be laid so that they are free of
tension and changes in length are not inhibited.

Generally pipe clamps with inserting tapes are to be used for fixing the pipes. These
tapes have to be adjusted to fit the outer diameter of the pipe and must fully surround
the pipe. Should no insertion tape be used, the interior edges of the clamps must be
rounded and the inner surfaces must be smooth.

66
 Installation

4.2 Procedure

67
also be provided to steady pipework between points

Horizontal pipework requires more frequent support than vertical pipework

Installation
Pipework should always be supported close to any change of directions (e.g. Bends
or branches)

4.3 Installing of pipe clamps

Smart Home waste water piping systems are always to be laid so that they are free of
tension and changes in length are not inhibited.

Generally pipe clamps with inserting tapes are to be used for fixing the pipes. These
tapes have to be adjusted to fit the outer diameter of the pipe and must fully surround
the pipe. Should no insertion tape be used, the interior edges of the clamps must be
rounded and the inner surfaces must be smooth.

Fixed clamps

By fully tightening the pipe clamps, fixed points (fixed clamps) are created in the
piping system.

They are therefore to be arranged in such a manner that any slipping of a pipe is
prevented. In the case of a pipe with a socket, the fixed clamp is to be installed
directly behind the socket.

Fittings and groups of fittings are to be fixed points at all times.

Loose clamps

Pipe clamps not completely tightened (loose clamps), when installed, must also allow
for a lengthways movement of the piping. Therefore, the inner diameter of the clamp
must be slightly greater than the outer diameter of the pipe after installation.

Spacing pipe clamps

For recommended pipe clamp spacing see table below

Nominal Outer Piping

Diameter (mm) Horizontal (m) Vertical (m)
32 0.5 1.2
40 0.5 1.2
68 50 0.5 1.2
75 0.8 2.0
Loose clamps
Installation
Pipe clamps not completely tightened (loose clamps), when installed, must also allow
for a lengthways movement of the piping. Therefore, the inner diameter of the clamp
must be slightly greater than the outer diameter of the pipe after installation.

Spacing pipe clamps

For recommended pipe clamp spacing see table below

Nominal Outer Piping

Diameter (mm) Horizontal (m) Vertical (m)
32 0.5 1.2
40 0.5 1.2
50 0.5 1.2
75 0.8 2.0
90 0.9 2.0
110 1.1 2.0
125 1.25 2.0
160 1.6 2.0

4.4 Laying piping in walls

The gaps in the walls are to be constructed in such a manner that tension-free
installation is possible.

Insofar as the pipes are directly covered in plaster, i.e. without using a plaster support
or a covering, the pipes must be completely sure rounded by ductile materials such as
corrugated paper or board, mineral wool or glass wool.

Respective measures must be taken (insulating the heat-conducting pipes, for example
heating pipes) at points at which higher temperatures may occur as a result of external
influences.

Horizontally-laid pipes (connecting pipes or collecting connecting pipes) which, for

example, serve as a connection for several installation elements for installation outside
walls, should be lined over their entire length. On doing so, extension of the length of
pipes and fittings is not to be inhibited.

4.5 Special application

The systems are more than adequate for normal domestic applications in low and
high rise buildings. Where more specialized applications, such as hospitals, industrial
kitchens and laboratories are concerned, where prolonged discharges of liquids at
elevated temperatures can occur.

4.6 Use of short lengths of pipe

PVC-U pipe may be cut on site when shorter lengths are required to suit the
installation, or for the installation of fittings.

The cutting of PVC-U pipe is easily achieved using a fine-toothed handsaw or a

PVC-U pipe cutter. The position of the cut should be measured and carefully re-
69
checked before cutting: reasonable accuracy should be exercised to ensure that the
 kitchens and laboratories are concerned, where prolonged discharges of liquids at
elevated temperatures can occur.

4.6 Use of short lengths of pipe Installation

PVC-U pipe may be cut on site when shorter lengths are required to suit the
installation, or for the installation of fittings.

The cutting of PVC-U pipe is easily achieved using a fine-toothed handsaw or a

PVC-U pipe cutter. The position of the cut should be measured and carefully re-
checked before cutting: reasonable accuracy should be exercised to ensure that the
cut is square to the axis of the pipe and all burrs must be removed from the cut end
before making a joint.

4.7 Trenching
There are a lot of important notes must take inconsideration for underground
installation of PVC drainagepipe in trench construction:-

• Excavation should comply with all applicable laws and regulations.

• Excavated material such as debris and removed pavement is not suitable for
trench backfill.
• Where dewatering is necessary, water should be removed until the pipe has
been installed and the backfill has been placed to a sufficient height to prevent
flotation of the pipeline.
• The maximum earth load on flexible pipe is the weight of the material directly
over the pipe (prism load). Unlike rigid pipe, the width of the excavated trench
does not affect pipe loading. Trench width is based solely on practical and
economical construction.
• See Figure 3.1 for trench terminology.

70
 Installation

Foundation

A foundation is necessary only when native soils are unstable. For such conditions,
the trench is over-excavated and a layer of supportive material is placed and
compacted to provide a firm foundation for the subsequent pipe embedment
materials.

Embedment

This zone is the most important in terms of pipe performance. It is divided into the
following subzones:

Bedding

Typically four to six inches of supportive, compacted material. This zone provides
even support for the pipe and brings it to grade.

Haunching

Extends from the bottom of the pipe to the centerline of the pipe (spring line). It
provides the most resistance to pipe deflection. Specifying proper materials and
compaction are most important for this zone.

Initial Backfill

Extends from the spring line to a point above the top of the pipe. This zone provides
some pipe support and helps to prevent damage to the pipe during placement of the
final backfill. The cover extends from the top of the pipe to the top of the initial
backfill. The depth of cover should be as much as necessary to protect the pipe during
placement of the final backfill. Twelve inches is a common depth of cover.

Final Backfill

This zone extends from the top of the initial backfill to the top of the trench. This
zone has little influence on pipe performance, but can be important to the integrity of
roads and structures.

Installation Trenches

Trenches should be excavated in accordance with plans and specifications. They

should be as narrow as practicable at the level of the top of the pipe and, in a straight

71
 Installation

trench, have a bed width not less than 200mm wider than the pipe diameter or three
time pipe diameter, to provide working space for the laying crew.

Trenches when excavated are either 'stable' or 'unstable'. The category into which a
trench fits is affected by the soil conditions, width, depth and method of excavation.
To ensure that maximum support is given to the buried pipe by the undisturbed
ground the resultant stable or unstable trench should be treated.

4.7.1 Stable conditions

Stable conditions are those where, after excavation, the trench walls remain solid and
do not show any signs of collapse or cave-in. Under such conditions the
recommended trench widths are shown in the following table:

Pipe Diameter (mm) Normal Width (mm)

100 400
160 600
250 750

4.7.2 Unstable conditions

Unstable conditions are those where, during or after excavation, the trench walls tend
to collapse and cave-in. Under these conditions, in open or unrestricted areas, the top
of the trench can be widened until stability is reached. A smaller trench should then
be dug in the bottom of the excavation to contain the pipe as shown. In areas where

72
 Installation

space is limited, e.g. in streets, it may be necessary to support trench walls by timber
or other suitable shoring.

4.7.3 Trench depths

The minimum trench depth should be such that pressures created by the weight of fill
material plus anticipated traffic or other superimposed loads will not damage the
pipes. As a guide the recommended minimum clear cover above is listed below:

Condition Min Cover Depth

Where no subject to vehicular loading 300 mm
Where subject to vehicular loading
Under driveways 450 mm
In sealed roadways 600 mm
In unsealed roadways 750 mm

4.8 Laying and Compaction

4.8.1 Preparing the trench
The trench bottom should be as level as possible, so that the barrel of the pipe is fully
supported along its whole length. In good working conditions, sandy or loamy soil,
the trench bottom can be made sufficiently even with stones and rocks removed to
provide continuous support for the pipes without the need of under-bedding.
4.8.2 Wet conditions
In wet ground, sloppy working conditions can be alleviated by first placing a layer of
hard granular material, or by de-watering the area in and around the trench. If patches
of ground are so wet that there is a risk of subsidence and possible damage to sections
of the pipeline, these areas should be consolidated by the addition of suitable fill
material.

73
 Installation

4.8.3 Trench installation

The trench should be excavated deeply enough to allow for the specified grade, the
required depth of bedding, and the minimum cover over the pipe.
The figure below suggests the following typical installation in a trench.

The following materials are suitable for bedding and overlay in the trench:
• Suitable sand, free from rock or other hard or sharp objects.
• Crushed rock or gravel of approved grading up to a maximum size of 14mm
• The excavated material, if it is free from rock or hard matter and broken up so
that it contains no soil lumps having any dimension greater than 75mm which
would prevent adequate compaction of the bedding.
• Cement mortar, containing one part of cement and four parts of sand by
volume, mixed with clean water to a workable consistency (bedding only).
4.9 Completing site work
Once the pipe is laid in the trench backfilling can commence. Two distinct phases are
involved with pipelines:

• backfilling prior to testing the pipeline

• backfilling after testing the pipeline

74
 Installation

Backfilling usually follows pipe installation as closely as possible in order to protect

the pipe from external damage, to eliminate the possibility of the pipe floating due to
flooding of open trenches, and to avoid shifting the pipe out of line due to cave-in.

It should be remembered that the purpose of backfilling is not only to protect the pipe
by covering it, but to provide firm continuous support under the pipe. Where concrete
or mortar bedding has been used, however, the bedding must have obtained its
required strength prior to backfilling.

4.10 Initial Backfilling

The first step in providing firm continuous support for the pipeline is to tamp soil
solidly under the entire barrel of the pipe, care being taken not to disturb the grade.

This backfilling material should be free from stones, rock or clay. When this is not
available other suitable material e.g. loamy earth or sand, should be taken to the site.
The initial backfill should be placed by hand shovel in layers not exceeding 300mm
deep. Each layer should be well tamped round and under the pipeline using the long
tamper illustrated. In this way air pockets are eliminated from beneath the pipe.

The layers should be shovelled in and tamped, the process being repeated until the
pipe is firmly bedded.
The flat tamper illustrated is used to consolidate this fill to heights of 300mm above
the top of the pipe for diameters up to 300mm.
The illustrations A and B below show the wrong and right ways of tamping the initial
backfill.

75
 Installation

In case A, too much soil is present and the tamping bar cannot compact it properly
leaving a void underneath the pipe.
Case B, shows the correct fill of a 100mm layer of soil which can be compacted to
form a firm bed for the pipe.

Pipe joints should be temporarily left exposed when placing the initial backfill, to
enable pressure tests to be carried out. After testing the line, backfilling and final
filling may be completed.

4.11 Testing and Inspection

Once the roughing-in is completed on a Smart Home system,it is important to test
and inspect all piping for leaks.Concealed work should remain uncovered until the
requiredtest is made and approved. When testing, the system shouldbe properly
restrained at all bends, changes of direction, andthe end of runs.
There are various types of procedures used for testinginstalled plastic systems.
However, a water or hydrostatictest is a technically superior test method for
inspectinga completed PVC-U piping system installation and is thetesting procedure
recommended by plumbing codestandards. The purpose of the test is to locate any
leaks atthe joints and correct them prior to putting the system intooperation. Since it
is important to be able to visually inspectthe joints, a water test should be conducted
prior to closingin the piping or backfilling of underground piping.

Water Test
The system should be properly restrained at all bends, changes of direction, and the
end of runs. To isolate each floor or section being tested, test plugs are inserted
through test tees in the stack. All other openings should be plugged or capped with
test plugs or test caps.
Fill the system to be tested with water at the highest point. As water fills a vertical
pipe it creates hydrostatic pressure. The pressure increases as the height of the water
in the vertical pipe increases. Filling the system slowly should allow any air in the
system to escape as the water rises in the vertical pipe. All entrapped air in the system
should be expelled prior to the beginning of the test. Failure to remove entrapped air
may give faulty test results.

76
 Installation

Once the stack is filled a visual inspection of the section being tested should be made
to check for leaks. If a leak is found, the joint must be cut out and a new section
installed. Once the system has been successfully tested, it should be drained and the
next section prepared for testing.

4.12 Completing Final Backfill

After testing of the pipeline, selected material should be hand shovelled over each
exposed joint and tamped to give 300mm minimum cover. Final backfilling to
ground level can be completed by hand or machine, using the soil originally
excavated from the trench. Care should be taken to exclude large rocks and stones
from the final backfill.
4.13 Pipe assembly
4.13.1 Basic Principles of Solvent Cement Welding
• The joint surfaces must be softened and remain wet with solvent cement during
joint assembly.
• Sufficient solvent cement must be applied to fill the gap between the pipe and
fitting.
• Assembly must be made while the surfaces are still wet and the solvent cement
is still fluid.
• Joint strength develops as the solvents evaporate from the joint.
• Cleaner primer must be used to prime and clean all jointing surfaces, prior to
application of solvent cement. No exceptions. Cleaner primer softens the
surface and is essential to a successful jointing process.
• Do not prepare the surface using sand paper as contamination can occur.
• No additive of any kind should be introduced to the cleaner primer, or to the
solvent cement. Ensure that the solvent cement is in good condition and runs
freely from the brush.
• If the cement does not run freely or appears “globular” or “tacky”, discard and
use fresh stock of solvent cement.
• Ensure that the cement is within its recommended “use by” date.
• In cold weather conditions, solvents penetrate and soften the PVC surfaces
much slower. Therefore, it is more important to pre-soften the jointing surfaces
with cleaner primer. Because of slower evaporation of the solvents a longer
cure time will be necessary.
• We recommend the use of disposable polyethylene gloves when applying
cleaner primer and solvent cement fluids.
• Solvent cement and cleaner primer are highly inflammable liquids and should
be kept away from all sources of ignition, they may be harmful if swallowed or
inhaled and may cause skin or eye irritation. Avoid breathing the vapor, use in
well ventilated areas.

77
78
Dimension - Measurements - weight

CHAPTER 5
Storage

5.1 Storage
5.2 Handling
5.3 Transportation

79
 Storage

Storage, Handling and Transportation

5.1 Storage
The following recommendations relate to the storage of Smart Home PVC-U pipes
under the normal climatic conditions.

• Pipes should be uniformly supported throughout their length, if this is not possible
timber battens at least 75mm wide at spacing’s not greater than 1m centers should be
placed beneath the pipes. Preferably pipes of different sizes and wall thicknesses
should be stacked separately. Where this is not possible the pipes with larger
diameters and thicker walls should be at the bottom. It is preferable that pipes should
not be stacked one inside the other.
• Pipe stacks should not exceed 7 layers with maximum height of 1m.
• Ideally, stacks should contain one diameter pipe size only. Where this is not possible,
stack largest diameter pipes at base of stack. Small pipes may be nested inside larger
pipes.
• If stored in the open for long periods, or exposed to strong sunlight, cover the stack
with opaque sheeting.
• Store fittings under cover. Do not remove from cartons or packaging until required.
Store solvent cement and cleaning fluid in a cool place.
• Ultra-violet light can affect pipes and fittings: pipe color may change

80
 Storage

5.2 Handling
Pipes made from PVC-U are strong, though lightweight and are therefore very easily
handled. However, it is necessary to take care to prevent damage; in particular, pipes
should not be thrown, dropped or dragged along. If pipes are moved by rolling it is
necessary to support them along their length and properly restrain them on inclines.

If pipes are loaded or unloaded by mechanical means (forklift, crane etc.,) care
should be taken to prevent damage. Pipes should be properly supported in two places
when lifted. Preferably protected slings should be used, if metal chains and hooks are
all that is available, padding should be placed between them and the pipes. If pipes
are delivered stuffed, special care should be taken to avoid damage during unloading.

• Take all reasonable care when handling PVC, particularly in very cold
conditions when the impact strength of the material is reduced.
• Do not throw or drop pipes, or drag them along hard surfaces.
• In case of mechanical handling, use protective slings and padded supports.
Metal chains and hooks should not make direct contact with the pipe.

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 Storage

5.3 Transportation
• Vehicles with a flatbed should be used for the transport of pipes. The bed
should be free from nails or other projections. Each pipe should be supported
uniformly along its length. Vehiclesholds have adequate side supports at not
more than 1.5m centers and pipes should be well secured during transit. All
uprights should be flat and free from sharp edges.
• Pipes should be loaded onto vehicles in such a way that any overhang does not
exceed 1m.
• Thick walled pipes must be loaded before thin walled pipes.

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