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
Release - January 2008
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
Release - January 2008
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
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Release - January 2008
* UV … UV resistance stabilized* FR … Flame retardant stabilized
Detailed technical values are shownin the applicational data sheet PP
3PPR - TECHNICAL Documentation
Release - January 2008
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
4PPR - TECHNICAL Documentation
Release - January 2008
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.
5PPR - TECHNICAL Documentation
Release - January 2008
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
6PPR - TECHNICAL Documentation
Release - January 2008
!
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.
7PPR - TECHNICAL Documentation
Release - January 2008
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
9PPR - TECHNICAL Documentation
Release - January 2008
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
10PPR - TECHNICAL Documentation
Release - January 2008
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.
11PPR - TECHNICAL Documentation
Release - January 2008
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
12PPR - TECHNICAL Documentation
Release - January 2008
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
13PPR - TECHNICAL Documentation
Release - January 2008
NO
NO
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