Toilet PLUMBING WORK

General
Plumbing Definition:
Introduction:

Vertical Concealed Toilet CPVC Piping:

CHLORINATED POLY VINYL CHLORIDE [CPVC] pipes and fittings are made from the specialty plastic,
chemically known as Chlorinated Poly Vinyl Chloride [CPVC]. This CPVC compound shall meet cell class
23447 B as defined by ASTM D1784 and have a design stress of 2000 PSI and a maximum service
temperature upto 93C. Pipes are produced in copper tube size (CTS) from 15 mm () to 50 mm (2)
with two different standard dimensional ratios - SDR-11 and SDR-13.5. The fittings are produced as
per SDR 11. All Astral CPVC SDR 11 and SDR 13.5 pipes are made from identical CPVC compound
material having same physical properties. The CPVC fittings are manufactured from compound
material which meets all the requirement as per ASTM standard. CPVC pipes of Copper Tube Size (CTS)
dimensions can also be applied to CPVC (IPS) dimensions by using IPS x CTS fittings. The CPVC pipes
from 15 mm () to 50 mm (2) are also produced as per IS 15778 standards in both class that is Class
1 (SDR 11) and Class 2 (SDR 13.5). Apart from having the same physical properties, SDR 11 and SDR
13.5 which are having different wall thickness and therefore, at any given temperature, they have
different pressure ratings.

CPVC Joint (Solvent Cement Application) :

Use only CPVC cement or an all - purpose cement conforming to ASTM F 493 or joint failure may result.
When making a joint, apply a heavy, even coat of cement to the pipe end. Use the same applicator
without additional cement to apply a thin coat inside the fitting socket. Too much cement can cause
clogged water ways.

Material of piping
Vertical & Horizontal Concealed pipe - CPVC
CPVC -Class 23447B as defined ASTM by D1784
Chlorinated Poly Vinyl Chloride - SDR 11: (15 mm) to 2 (50 mm)CTS
Pipes & Fittings - SCH 40: 2 (65 mm) to 12(300 mm)IPS.

Fittings: -
Coupler, Reducing Coupler, Union, Equal Tee, Reducing Tee, Elbow 90, Elbow 45, Reducer, End Cap,
Male & Female Adapter.

CPVC Pipe Joint Solvent Cement Application: -

Adhesive Solution (Yellow) - Adhesive Astral N.B. For sizes 15 mm(1/2") to 50 mm(2")
CPVC 724 - Adhesive Astral N.B. For sizes 65mm(1/2) and above
Primer P70 - Adhesive Astral N.B. Must use primer for 65mm(2 1/2") & above
Supports: - Clevis Hanger , Threading Rod.
TOOLS :

A. Drill, Chasing Machine, Spirit Level, Hammer, Drill Bit, Grinding wheel, File, Measuring tape,
Pressure Testing Machine & dial gauge
B. Chisel, screw driver, hammer drilling M/c, Mini angle grinding M/c. block core m/c .

Procedures of Installation Horizontal & Vertical Toilet Piping:

Approved drawing for Water Supply layout to be checked for routing of pipes and setting out
dimensions with respect to column grids
Routing of pipe to be identified and marking of the route to be done on ceiling or on the wall
by using colored line dory as per approved co-ordinated drawing.
Bottom of pipes to be checked from approved drawings and pipe supports to be installed as
per approved drawings using approved clamps from ceiling in a way that the system can be
drained from the bottom most point.
Chase for concealed water services to be done in Block work as per approved drawings for all
sanitary wares and fittings.
Required number of CPVC pipes and fittings as per approved drawings to be kept ready for
installation.
CPVC pipes to be installed on the supports horizontally as per approved drawing for water
supply & lay outing to be done as per routing of pipes and setting out dimensions with respect
to column grids .
CPVC pipes to be embedded with PVC clamp support at every 1 m as required in block work
chase with reference to tile marking and install as per approved drawings for all sanitary wares
and fittings as indicated on catalogue.
Cover the CPVC pipes with 1:3 c:s non shrink mortar.
Horizontal CPVC pipes to be connected to Vertical concealed CPVC pipes by Solvent Cement.
The above installation has to be pressure tested for leaks at least 10 kg/cm2 pressure for 4
hours.
System to be hydraulically tested as a whole or in parts as per the progress of the work at site.
System to be checked visually for installation as per the approved drawings. All open end of
pipes is to be closed by using plugs of required size and an automatic air vent to be installed
at the highest point to vent out air. Pressure Gauges to be installed at the lowest and highest
levels. Water is slowly pumped into the system till the pressure reaches at least 10 kg/cm2
pressure for the system and observed for 4 hours. Leaks, if any, are rectified after the system
is drained and to be pressurized again. The test set up is observed for 4 hours again and the
test is to be scheduled for inspection by the Shimizu for witness test. After the pressure test
is approved, the pipe ends are sealed by plugs so that foreign material does not enter the
system. Prior to pressure test necessary venting of air trapped inside the piping section will
be carried out until air less water spills out.

Procedures of Vertical Concealed CPVC Piping:

The Location and routing of water supply pipes shall be marked as per the approved drawings.
Mark on the wall, the routing of the vertical pipes (CPVC) to each sanitary fixtures & as per
Tile Marking.
Chase the wall sufficient enough to conceal the cold water CPVC pipes.
The pipes shall be cut to required length and the ends shall be slightly chamfered removing
burs.
Install the CPVC pipes with clamps PVC or approved at every 1 mtr
 The pipes and fittings with valves shall be joined as per requirement.
Connect the vertical CPVC pipe to header pipe for cold water which runs above false ceiling.
All the pipes shall be pressure tested for leaks at least 10 kg/cm2 pressure for 4 hours, pressure
gauge to be installed at one end and note the time with pressure after 4 hours of time again
the pressure to be checked.
All open ends of pipes will be protected with temporary protective plugs during the
construction.

Procedures of Vertical & Horizontal Concealed CPVC Piping:

1.Ensure that there is sufficient space to permit access to the joining area.
2.Cover the pipe ends remote from the fitting joint to ensure airflow through the pipeline cannot occur
during the heating and cooling cycles.

Joining Pipe and Fittings:

CUTTING:
3.Always use a good quality pipe cutter.Check that the pipe end to be jointed are
4.In order to make a proper and neat joint, measure the pipe length accurately and make a small mark.
Ensure that the pipe and fittings are size compatible. You can easily cut with a wheel type plastic pipe
cutter or hacksaw blade. Cutting tubing as squarely as possible provides optimal bonding area within
a joint.

DEBURRING / BEVELING:
5.Burrs and filings can prevent proper contact between tube and fitting during assembly and should
be removed from the outside and inside of the pipe. Debarking tool, pocket knife or file are suitable
for this. A slight bevel on the end of the tubing will ease entry of the tubing into the fitting socket
 FITTING PREPARATION :
6.Using a clean, dry rag, wipe dirt and moisture from the fitting sockets and tubing
end. The tubing should make contact with the socket wall 1/3 to 2/3 of the way
into the fitting socket.

SOLVENT CEMENT APPLICATION :

7.Use only CPVC cement or an all - purpose cement conforming to ASTM F 493 or joint
failure may result. When making a joint, apply a heavy, even coat of cement to
the pipe end. Use the same applicator without additional cement to apply a thin
coat inside the fitting socket. Too much cement can cause clogged water ways.

ASSEMBLY :
8.Immediately insert the tubing into the fitting socket, rotate the tube to
turn while inserting. This motion ensures and even distribution of cement within
the joint. Properly align the fittings. Hold the assembly for approximately
10 seconds, allowing the joint to set-up.
SET AND CURE TIMES:
9.Solvent cement set and cure times are a function of pipe size, temperature and
relative humidity. Curing time is shorter for drier environments, smaller sizes
and higher temperatures. It requires 10 to 20 minutes for perfect joint

Acceptance of Completed Work

Internal Plumbing & Internal Drainage:

Type of Check Acceptance

Position of: WHB, EWC, Bath tub, Flush tank, As per Architectural Drawing
Boiler w.r.t. FFL and walls.
Position of Nahani Trap As per Architectural Drawing
Holes / Chases in Masonry Made by only block core machine & Rendered
with non-shrink grout
All traps Position and level as per Architectural Drawing
Functioning of: Water flow found satisfactory with enough
Ablution tap, Angle stop cock, Long body bib pressure
cock (Kitchen sink), Dry balcony bib cock, Mixer
shower, Flushes, Basin pillar, Basin mixer cock,
Nelson valve, Control valve
All above taps checked after locking No leakages observed
Pressure Testing Satisfactory