ENGLISH MANUAL 2008

www.plastofer.it

SISTEMA DI GESTIONEQUALITA' CERTIFICATO

TEC

HN

ICA

LM

AN

UA

L012008 ENGLISH

Il Sistema di Qualità è conforme alla norma UNI EN ISO 9001:2000, per le seguenti attività:

Progettazione, produzione e commercializzazione di tubi e raccordi in polietilene e polipropilene per impianti idrici ed idrosanitari.

CERTIFICAZIONE DEL SISTEMA DI QUALITÀ AZIENDALE

INTERAZIONE TRA I PROCESSI PRODUTTIVI PLASTOFER

PPR - TECHNICAL Documentation

Release - January 2008

SISTEMA DI TUBAZIONE E RACCORDERIA IN PPR PER

IMPIANTI DI TIPO IDROSANITARIO

INDEXPLASTOFER SYSTEMFIELDS OF EMPLOYMENTOPERATING FEATURESPROPERTIES OF RAW MATERIALMATERIALS RESISTANCE VALUESINSTRUCTIONS FOR WELDING THROUGH ELECTRICAL SLEEVETEST OF THE SYSTEMRECOMMENDATIONS FOR THE INSTALLATIONLOSS OF PRESSURETHERMAL EXPANSIONFIXED AND SLIDING POINTSLENGTH VARIATIONSEXPANSION COMPENSATORSLENGTH OF THE COMPENSATIONINSTALLATION OF FIXED AND SLIDING POINTSPLASTOFER GUARANTEEPLASTOFER SYSTEM CERTIFICATERECOMMENTDATIONS FOR PIPES MOVEMENT AND STORAGEWARNINGS FOR THE RIGHT USE OF THE SYSTEM

PPR - TECHNICAL Documentation


Plastofer system

Plastofer system produces pipes and fittings for cold and warm water-main for buildings.The raw material we use is polipropilene random - type 3 - for products that go in touch with every alimentaryliquid.There is no difficulty to install the system.It is enough to use the right equipment and respect the conventionalprocedure.The advantages of Plastofer system products are a lot :they are heat and chemical agents resistant, limestone proof, they assure low thermal conductivity and lowfriction, pressure assuring lightness and easiness in the use too.

Fields of employment

Plastofer products can be used for hydro-sanitary system (UNI - EN - ISO - DIN) in big and small buildings,for water-main system on boats, heating system through radiators.

Operating features

DrinkablenessPlastofer products respect the rules for potability water systems.

Easy installationPlastofer system is easy to install and its low specific weight consent to be moved and installed in everysituation.

Sound-proofingPlastofer pipes and fittings give an high sound-proofing even in case of water hammerings.

WeldabilityPlastofer system materials consent the junction of every element through multifusion welding or easily usingan electrical sleeve.

Saving energyPlastofer pipes allow about 15 % of energy saving, thanks to the low loss of heat.

1PPR - TECHNICAL Documentation


Erasure-proof and corrosion-proof Plastofer system allows the liquids to flow up 7 m/s causing no problems eventhough they are acids or alkalinematerial with a ph between 1 and 14.

Low temperature resistance There is no problem in case of low temperature (ice), because although the augment of volume in the liquid,Plastofer materials are enough flexible and adaptable to afford low temperature.

Regulations and certifications for Plastofer pipes and fittings

Properties of raw materialFor pipes and fittings, Plastofer uses Polipropilene random, a crystalline polymeride ; cause of its resistanceto high temperatures it is used for thermoplastic pipes.Polipropilene random is non-toxic, it is produced according to the ministry of health rules for the utilizatin ofproducts that go on touch with alimentary liquids.Polipropilene random also passed the pressure and endurance tests done by SKZ, a German Institutewhich gives reports of approval for plastic materials and by other important Institutes for officialacceptance.

Phisical properties and mechanical characteristics

Characteristics U<nit Method Value

Density 23°C g/cm3 ISO 1183 0,900

MFR 190°C 5 Kg g/10 min ISO 1133 0,55

MFR 230°C 2,16 Kg g/10 min ISO 1133 0,25

Tensile modulus N/mm2 ISO 527 900

Volume MVI 230/2,16 cm3/10 min ISO 1133 0,38

Notch impact strength 23 °C KJ/m2 ISO 179/1eA 31

Notch impact strength -20°C KJ/m2 ISO 179/1eA 2,2

High temperature stabilized •Resistance to hot detergents •

Specially stabilized

UNI 9182 Dimensions of water-main

UNI 8318 Dimensions of polipropilene pipes

UNI 8321 Polipropilene pipes, tests methods

DIN 1988 Rules for hidro-sanitary systems. Tests

DIN 4109 Sound proofing in private buildings

DWGW 308 Regulations about calculation of water-main

DIN 8077 Dimensions about thickness of polipropilene pipes

DIN 8078 Polipropilene pipes - type 3 - characteristics tests

DIN 8076 Tests for fittings

DIN 16962 Fittings for polipropilene pipes

DVS 2207 Weldingsof termoplastic materials by means of heating tools

DVS 2208 Machines and engines to meld plastics through heating elements



* UV … UV resistance stabilized* FR … Flame retardant stabilized

Detailed technical values are shownin the applicational data sheet PP



Resistance of materials

Plastic materials turns towards puckering when subjected to mechanical tension, fixing the allowed tensionand subjecting plastic materials to tension during the time, one has to observe the behaviour of the plastics.Herebelow in the diagram it is possible to observe the proceeding of tests done on polipropilene pipes andtaking out values from the herebelow table:

REGRESSION CURVE IN PPR PIPES - TYPE 3

Endurance values through the time at different temperature and pressures

Temperature( °C )

Endurance whileworking(years )

Pressure(bar)

Coefficent ofsafety

20 50 20 1,9

< 40 50 20 1,3

< 60 50 12,6 1,3

< 80 20 7,8 1,3

< 95 10 5,9 1,3

Tempo in oreTempo in ore

Tens

ione

in N

/mTe

nsio

ne in

N/m

22

101011 101022 101033 101044 101055 101066

11 1010 5050

101000101000

22

33

44

55

66

77

8899

1010

2020

3030

4040

5050

Durata in anni

11011000

959500

808000

707000

606000

505000

404000

101000

303000

202000

Instructions for multifusion weldingMultifusion welding consist in heating at the same time the male and the female part of pipes, connectingthem perfectly with watertight seal.Before welding look carefully at the pictures below and use proper equipement; be sure the surfaces youhave to weld are smooth, without impurities and remember the cut must be perfectly perpendicular, (Picture1), then check the temperature of the welder reached the suitable level.The heated pipe and fitting have to be connected up to the advised depth and holding tight and still withoutany rotation (picture 4).Respect correct connection depth not overtaking the final point in the fitting.

Pipe outsidediameter

(mm)

Fitting depth(mm)

Heatingtime (s)

Working time(s)

Cooling time(min)

20 14 5 4 2

25 15 7 4 2

32 16,5 8 4 2

40 18 12 6 4

50 20 18 6 4

63 24 24 8 6

90ϒ

Picture 1: Cut of the pipe Picture 2 : Marking

Picture 3 : Heating Picture 4 : Connection

Cut the pipe perpendicularly withspecial scissors

Mark the connection depth on the pipe

Heat the 2 sections when they areperfectly aligned

Join the 2 sections without any rotation andnot overtaking the final point in the fitting

TIMES OF WORKING



Instructions for welding through electrical sleeve

Clean and remove the grease from the sections to connect, line the pipes and then insert them in thesleeve, switching the welder and introducing plugs into the sleeve holes.Once the welder is on, the process will be automatic.During the welding, be careful not to subject pipes to tension and once the welding is over be careful notto cool the connection artificially.It is very easy to use this kind of welding; it is particularly suitable for repairing parts of the working plant.

Test of the systemTest is about traditional kind of plant. Before beginning the test, check there is no broken point and verify thepipe is not subjected to tension.

Test resultA good result of the test is the lack of losses, neither humidity.The plant must be watertight.

WarningsAfter testing, empty the plant completely , expecially with temperature under 0°C. During the test, if the roomtemperature rises of about 10 °C, the pump pression can vary of about 0,5/1 bar.

Recommandations for the installation

Plastofer system gives the opportunity to spare time while installing and testing, thankingto the high quality of the product, to the easiness in the use.In this page there are some advice for installation.

PlanningUse and strictly respect tables calculation you find in the catalogue.

MaterialsPlastofer system does not imply the choice of specific accessories or materials for installation.

PipelineAvoiding condensation : place hot water pipes above the cold water pipes. Installation of pipes is better tobe done upwards, towards the joining point. Avoid air into the pipes.

Controlling the plant1 – FILLING THE PLANT

Fill the pipes with clear room temperature water, checkthere is no air into the pipes.

2 – INTRODUCTORY TEST

Charge the pump with 25 bar keeping this pressureone hour

3 – FINAL TEST

Charge the pump with 15 bar keeping this pressureabout 24 hours long.



15 bar for 24 yours

PUMP

Protective coatingsProtective coating of fixed and sliding points must cover pipes with rubber or pvc, so avoiding damages.

Combinations with conical cast-iron threadsBe very careful closing tightly fittings with metallic insertion.Avoid tighty closing most of all in joining conicalthreading.

Loss of pressure

The diagram below represents, in planning the suitable dimension of pipes to a net of water supply.The calculation assures the requires flow also in critical situations.

Mixed installation with metallic pipeline Insulating materials

Sliding points Fixed points



!

Picture 1

Pipe

Pipe

BracketSleeve or fittingRubber or PVC

Fittings resistance coefficentScheme

Thermal expansionPolipropilene pipes as any other plastic material tend to expand with temperature; therefore, while planninglarge or medium plants, it is necessary a very careful analysis of fixed and sliding points, of their positionand of any expansion curve.

Plants in conduits or in cementIt is advisable covering pipes with an insulating sheath, when pipes in conduits or underground are longer than2 mt. This solution enables to absorbe axial expansion, avoiding condensation and assuring a largernoiselessness.

Fixed and sliding pointsTo carry out a good plant one must know the location of the fixed points. They allow to divide the plant intothe expansion sections, avoiding an uncontrolled movement to the pipes Every element in the plant, suchas valves and specific connections must be fastened with fixed points.Occasionally fixed points can be located near wall crossing points or near branches. For the fixed pointsesistance it is necessary to take into account the weight of pipes, the weight of transported liquid and thestrength of linear expansion.

Sliding pointsThey have the aim of aligning and sustaining the plant, moreover they enable pipes axial sliding.When the pipeline is too long it is advisable to use supporting canals.

Flowing water meetsresistance due tosudden, abrupt change ofdirection.The nearby table showsthe resistance value forevery kind of used fitting.



Symbol Picture Resistancecofficent

Sleeve

Elbow 90°

Elbow 45°

Tee

Reduced tee

Threaded tee

Male threaded joint

Male threaded joint, reduced

Male threaded elbow

Male threaded elbow, reduced

Length variationsA pipe linear expansion, due to temperature can be calculated according to the following formula:∆l = d x L x ∆t

∆l = length variation in mmd = coefficent of linear expansion for pp=0,15L = pipe length in m∆t = temperature difference in °C

Pipe length variation according to temperature variation

Expansion ∆L mm

8P P R - T E C H N I C A L D o c u m e n t a t i o n

R e l e a s e - J a n u a r y 2 0 0 8

E X A M P L E O FF I X E D P O I N T E X A M P L E O F S L I D I N G P O I N T

P l a t eP i p e

S l e e v eB r a c k e t

F i t t i n g

P l a t e

P i p eB r a c k e tR u b b e r o f P V C

Tem

pe

ratu

re

∆t i

n °

C



To avoid unaesthetic undulations in visible external pipes, it is advisable to make a stirruping respecting thedistance shown in the diagram :

Expansion compensatorsIn the following pictures you can see 3 examples of expansion compensation. Installing visible or innercourtpipes very important is the stirruping in the wall.Curves and branches must be fixed with sliding points, either in vertical or in horizontal sections, so thatpipeline can freely expand.

L L

LS

FP LP

FP L L

LPFP

FP

LS

L

Example 1: Example of expansion in A pipelinesection near a curve.

Example 2: Example of expansion in A pipelinesection near an inner branch.

L L

LS

L L

FP LP

FP

FPLP

Legend:

∆l = length variationLP = sliding pointL = pipeline lengthFP = fixed pointLS = U-expansion joint length

Example 3: Example of U-expander compensator.

Diagramm

∆L

∆L ∆L

∆L ∆L



By-pass of a wall and of a solid column.Three examples of pipeline installed into a solid column.

Compensation section lengthThe compensation section length can be determined following the broken line shown in the underneathscheme or using the herebelow formula.

LS

LS

EXAMPLE 1 EXAMPLE 2 EXAMPLE 3

Tem

pera

ture

diff

eren

ce ∆

t °C

Min

imum

wid

th o

f the

c

ompe

nsat

ion

sect

ion

Lenght variation ∆L mm

LS = K . d . ∆L

Legend:

LS = compensation section lengthK = constant material x ILPP = 30d = pipe fsv diameter∆L= linear expansion

EX. :

polipropilene pipelineΦ 40 length ML 6∆t = 55 °C∆L= 0,16 x 6 x 55 = 52.8

LS = 30 . 40 . 52.8 = 138 cm

Scheme

Placing fixed and sliding pointsE’ bene, per un corretto ancoraggio della tubazione, utilizzare delle staffe fermatubo che non dannegginola superficie del tubo.I punti fissi devono resistere ai movimenti dell’impianto e devono essere posizionati presso valvole diintercettazione e giunzioni, per mezzo di manicotti o raccordi.

FP

I2

I1

I3

I4

Is4

Is3

Is2

Is1FP

Is4

Is1

Is2

Is3I4

I3

I5

I1

I2

Is5

Example 1: Example of placing a fixed pointat the ground floor.

Example 2: Example of placing a fixed pointat the first floor.

I1 I2 I3 I4

Example 3: Example of horizontal pipeline section with fixed points according to choice.Expansion is counterbalanced by a circular compensator and by an expansio curve.



Plastofer guarantee

Plastofer products are guaranteed for damages to persons or things caused by pipes and fittings withmanufacturing defects up to 1.500.000.000 , 10 years long from the date indicated on the pipe.Guarantee conditions are :

- Pipes and fittings must be installed according to the instructions of the techicalhandbook.- Pressure and temperature must be included among the technical values of that specificmaterial.- Weldings must be done only with the specific equipment.

To get the guarantee, mail section (A) to Plastofer SRL in ten days from the end of the testing, after fillingthe underneath certificate, section (B) must be kept with the fiscal receipt or similar document issued by theinstaller company and exibit it in case of complaint.

Side Ato be

mailed

Side Bto be kept

Facsimile of the guarantee certificate



Plastofer system certification

Recommendations for pipes movement and storage

There is no particular recommandation concerning transport.Pipes just have to be placed correctly andsteady into the motor vehicle To protect pipes and fittings from exposure to sun’s rays, (often the cause ofsudden damage) cover them when storing and installing.

Warnings for the right use of the system

Don’t heat the pipe. To make curves use the right fittings or by pass.To guarantee watertightness use teflon or liquid seal avoiding eccessive quantity of hemp.Use particular careness in installing, storing and moving pipes at low temperature, because polipropileneat temperature 0°C tends to be very fragile.

Every information you find in this catalogue can be subjected to variations.Plastofer has no responsability about the validity of the dates.

Picture 3 Picture 4

TC = PIESSE PPR DIN 8077/78 TIPO 3 Ø 20 x 3,4 PN 20 10 BAR 60ϒC

TC = PIESSE PPR DIN 8077/78 TIPO 3 Ø 20 x 3,4 PN 20 10 BAR 60ϒC

Picture 1 Picture 2



NO

NO

ENGLISH MANUAL 2008

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