In a building, the drainage system is an

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Jemimah Chase
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1 CAST IRON HUBLESS FOR BUILDING DRAINAGE SYSTEM B. PRAVEEN In a building, the drainage system is an arrangement prvided t cnvey the waste water thrugh assembly f drainage pipes and fittings fr Sil, Waste, Vent and Rainwater lines. This flw is under gravity and discharged t STP/public sewer and rain water t strm drain/rainwater harvesting pit r tank. PERFORMANCE REQUIREMENT OF PRODUCT FOR ANY BUILDING DRAINAGE SYSTEM General The prducts t be used in Building Drainage System shall cmply with the perfrmance requirement and service life fr which a building is designed. It shuld als cnfrm t Natinal r Internatinal Standards. In general, the drainage system shuld ffer - Durability Versatility Stability during cnstructin and peratin Accessibility fr inspectin Testing and maintenance Functin It shuld nt cause danger r nuisance nr endanger prperty such as the building structure, supply systems r ther appliances within the building with nrmal predictable use and shuld be easy t maintain. Hygiene The health aspects f the users and ccupiers f the building shuld nt be affected by: Leakage Waste water flding int the building Penetratin f txic gases r nxius drs int the building Cntaminatin f the drinking water frm the system Nise Safety Drainage system shuld ffer prtectin and safety against: Escape f drs Mechanical failure Frst Flding Preventin and spread f fire. Hubless Drainage System fits all these requirements Cast Irn pipes and fittings have been used t cnvey waste and water thrughut the wrld since centuries. Cast irn pipe installed at the funtains f Versailles in 1623 are still functining tday and is the silent testimny f durability and perfrmance. Cast irn has prven its wrth ver the years in demanding applicatins, a histrical track recrd unmatched by any ther material. 12 / Octber 2017 / Indian Plumbing Tday

The jinting f these pipes and/r fittings is dne with stainless steel shielded cuplings.

and lw nise. Custmers f past generatins chse cast irn fr its strength and durability.

Cast irn has undergne changes that put it at the tp f the list fr clients and custmers.

2 WHAT IS HUBLESS? Cast irn pipes and fittings are simply manufactured withut a hub r scket and are called Hubless pipes & fittings. The jinting f these pipes and/r fittings is dne with stainless steel shielded cuplings. Hub pipe and Hubless Pipe STANDARDS FOR HUBLESS DRAINAGE SYSTEM INDIA IS ISO 6594 EUROPE EN-877 GERMANY DIN WHY HUBLESS CAST IRON DRAINAGE SYSTEM? Tday s custmers chse hubless cast irn pipes & fittings because strength ges tgether with ease f installatin, fire resistance and lw nise. Custmers f past generatins chse cast irn fr its strength and durability. Nw, mdern hubless cast irn drainage system is cmpatible with state-f-the-art building techniques. Cast irn has undergne changes that put it at the tp f the list fr clients and custmers. Hubless cast irn drainage system installed wrldwide is functining flawlessly. The hubless cast irn drainage system is glbally accepted technlgy due t its numerus advantages and versatility and cmpared t ther alternative materials available in the market. This system is als getting gd ppularity and acceptance in the Indian market. Standards fr Hubless Drainage System Dueker Machine A Stack f Hubless Pipes Varius Fittings fr Hubless Pipe System Indian Plumbing Tday / Octber 2017 / 13

3 Fr hubless drainage system, ISO-6594 Standard is fllwed wrldwide. Based n this standard, ther lcal standards have been frmulated such IS in India, EN-877 in Eurpe, and DIN in Germany, etc. In hubless drainage system, the ends f pipe and fittings are plain and are jined with the help f S.S. Cuplings (SS 304 Grade) with EPDM rubber gasket. These cuplings are resistant t xidatin, warping and defrmatin and tgether with rubber gasket, it ffers leak prf jints t the system. These cupling jints allw a deflectin up t 3 degrees. The cuplings permit sufficient flexibility under adverse cnditins and allw pipe mvement, building sway mvement withut any leakages. It has an excellent prperty f resisting vibratin and absrbs the shcks. The hubless drainage system prvides a mre cmpact installatin withut sacrificing the quality and perfrmance f cast irn due t usage f cuplings fr jinting. Specific Weight Kg./ dm 3 Tensile Strength N/mm 2 (Min.) Hardness HBS (Max). C-Efficient f Expansin mm/m 0 K Crushing Strength N/mm 2 Mdulus f Elasticity - 10x10 5 N/mm 2 Temperature Resistance C (Withut Significant reductin In Mechanical Prperties) Material Grade FG 150 Grade, as per ISO 185 and IS 210 Standard The great advantage f system is that, it permits jints t be made in limited access areas and can even help in reducing the shaft sizes. This hasslefree system prvides significant cst benefits, since the pipes are available in lnger lengths and use f cuplings fr jinting, which resulting in fast and efficient wrk, every inch f pipe can be utilized, which reduces wastages. Installatin f hubless cast Irn pipes and fittings has n added cmplicatins like fire cllars, cladding, sund insulatin, expansin jints, thermal limiters, etc. which helps reducing the cst f verall system. Since light weight, hubless pipes and fittings are easy t handle. This system des nt require frequent and cstly maintenance. This is the nly system wherein each and every jint can be pened and the maintenance wrk can be dne. This system allws the rerientatin in drainage system in future als, since the cuplings used fr jinting pipes & fittings can be taken ut and the pipes and fittings can be reused and rejined. CI Hubless Sanitary Tee Cnnected t Hubless Pipe ADVANTAGES DUE TO TECHNOLOGICAL IMPROVEMENT Imprved metal quality Precisin casting with cntrlled tlerances Straight pipe Smther surfaces Mre unifrm wall thickness Standardized pipe and fitting dimensins prviding cmplete prduct interchangeability Assurance f lng-lived, ecnmical and truble-free service Lnger laying length Fast and easy cupling jints Lwer installatin cst SERVICEABILITY Cleaning f cast irn drainage system is easy and can be undertaken with push rds withut damage t the prduct There is n tendency fr drain lines t sag between supprts Alteratin r additins can be made easily with a minimum interruptin in system usage Strage, handling and maintenance are easy Sunlight, temperature extremes, r ageing has n effect n cast irn 14 / Octber 2017 / Indian Plumbing Tday

HUBLESS COUPLING : REVOLUTION IN DRAINAGE SYSTEM DESIGN STANDARD FOR SHIELDED COUPLINGS ASTM C 1277 IS 15905 Hubless cupling jints has revlutinized cast irn drainage pipe installatins frm hazardus,

S. cuplings streamlined the hubless drainage piping installatin prcess tremendusly, and can be dne with nly 10 minute training. A 304 series S.S. is used fr cupling because f its superir crrsin resistance.

As further tightening ccurs, pressure is exerted bth parallel and crss ways against inner EPDM Rubber gasket, tightening it against the pipe r fitting and prviding a slid reliable seal.

4 HUBLESS COUPLING : REVOLUTION IN DRAINAGE SYSTEM DESIGN STANDARD FOR SHIELDED COUPLINGS ASTM C 1277 IS Hubless cupling jints has revlutinized cast irn drainage pipe installatins frm hazardus, tedius, skilled craftsman trade, t a simpler, quicker, less tl needed, safer ccupatin. The inventin f S.S. cuplings streamlined the hubless drainage piping installatin prcess tremendusly, and can be dne with nly 10 minute training. A 304 series S.S. is used fr cupling because f its superir crrsin resistance. It is resistant t xidatin, warping and defrmatin, ffers rigidity under tensin with a substantial tensile strength and yet prvides sufficient flexibility. paths. As further tightening ccurs, pressure is exerted bth parallel and crss ways against inner EPDM Rubber gasket, tightening it against the pipe r fitting and prviding a slid reliable seal. Flating eyelets fastened the clamps t the shield, allwing the clamp band and shield t mve independently. This feature prevents the shield frm crimping during tightening. The stainless-steel shield keeps pipes aligned with each ther preventing sagging r shifting. The EPDM Rubber gasket creates the seal between the pipes r fittings and helps preventing pipes r fittings pulling ut f the cupling. EPDM Rubber seals help in reducing nise transmissin, since center stp prvides a psitive islatin break at every jint by preventing direct metal t metal cntact between the tw-plain edge f pipes and/r fittings. EPDM Rubber's value as an islating material has lng been recgnized by acustical engineers. This type f rubber is widely used fr engine munts and pads under nise prducing machinery such as pumps, chillers - cmpressrs, fans and ther equipment. S.S. Shielded Cuplings has mre width and hence, mre sealing area, which prvides extra strength t jints. JOINTING PROCESS SS Shielded Cuplings fr Hubless Pipe Cmpnents Of Shielded Cupling Jint The S.S. crrugated cupling shield is designed t adjust the variatins in diameters f hubless pipe r fittings t be cnnected. The clamps feature a ne-piece warm drive screw husing that mechanically interlcks the husing t the band. Due t tightening at bth ends, it eliminates leak MATERIAL FOR SHIELDED COUPLINGS Stainless Steel SS 304 Grade Rubber Gasket EPDM (Ethylene Prpylene Diene Mnmer The jint assembly cnsists f a specially designed Elastmeric Sleeve (EPDM gasket) which fits ver the end f the pipe r fitting and is clamped t the pipe r fitting with Stainless Steel (SS-304) shielded clamp. 1. Place the gasket n ne end f pipe r fitting & the stainless-steel clamp & shield assembly n the ther end f pipe r fitting. 2. Firmly seat the pipe r fitting ends against the integrally mlded center stp inside the EPDM rubber gasket. 3. Slide the stainless-steel shield & clamp assembly ver the EPDM rubber gasket and tighten the bands. Fr larger diameters Assembly cuplings, which have fur bands, 16 / Octber 2017 / Indian Plumbing Tday

the inner bands shuld be tightened first and then the uter bands. 4. In all cases, when tightening bands, they shuld be tightened alternately t ensure that the cupling shield is drawn up unifrmly.

5 the inner bands shuld be tightened first and then the uter bands. 4. In all cases, when tightening bands, they shuld be tightened alternately t ensure that the cupling shield is drawn up unifrmly. CUTTING PROCEDURE shuld be prvided at each jint fr each cupling t allw fr cntinuus supprt f the barrel alng the trench bttm. If the ditch must be excavated deeper than the depth f the drainage pipe, place and tamp backfill material t prvide unifrm supprt fr the pipe barrel. Many times, in the installatin f undergrund cast irn, it is necessary t make adjustments t the directin f the drain line. Cast irn hubless pipe and EPDM rubber gaskets will allw this thrugh deflectin in the jints. Installatin shuld initially be cmpleted in a straight line and then deflected t the apprpriate amunt. Maximum deflectin shuld nt exceed 12mm per 300mm f pipe length. This wuld allw 120mm f deflectin fr a 3000mm f pipe length. Fr changes in directin greater than these deflectins, an apprpriate fitting shuld be used. Cutting Machine Fr cutting hubless cast irn pipes and fittings, cutting machine is recmmended (as shwn in figure abve), which saves time and cuts the pipe/fitting perpendicularly with straight edges. Remve the burrs, if any, after cutting. PROCEDURE: Mark the pipe surface frm where the pipe shuld be cut Fix the pipe in machine vice Nw mve the cutting wheel dwnwards till the pipe is cut UNDERGROUND INSTALLATION The physical prperties f cast irn sil pipe and fittings make cast irn an ideal drain, waste, and vent material fr undergrund installatins. Tw key elements fr prper undergrund installatins are trench preparatin and backfilling. The trench shuld be wide enugh fr easy assembly f the jints. Ttal lad n the pipe includes bth earth lad and live lad. Safety prcedures and ther laws applicable t trenching shuld be bserved, including prvisins t avid cllapse f the trench wall. Cast irn, being a rigid material, des nt depend upn side fill fr supprt. The trench bttm shuld be stable enugh t supprt the cmplete barrel f the pipe. If pssible, the barrel f the pipe shuld rest n even and undisturbed sil. Hles Once the undergrund installatin is cmpleted, the sectin is ready fr testing. Testing at 3000mm head f hydrstatic site test pressure (0.03 MPa) is recmmended. Since, the undergrund drainage pipe is usually the largest diameter pipe, it is necessary t restrain the system r jints frm mvement at changes in directin and end f runs prir t testing. This may be dne by partially backfilling and leaving the jints expsed fr inspectin. After testing is cmpleted, the trench can be prperly backfilled. When backfilling, care shuld be taken t prtect the pipe frm large rcks, stnes, r frzen fill material that culd damage the pipe. Cast irn sil pipe laid n a slid trench bttm des nt require special backfilling r prcedures. It shuld be prperly assessed, bserved, tested and determined befre laying cast irn pipes undergrund that, whether it requires plyethylene encasement because f crrsive nature f sil in cntact. Installers shuld always cnsider lcal cnditins, cdes and engineers instructins fr undergrund installatin. UNDER SLAB INSTALLATION: Althugh cast irn sil pipe, fittings, cuplings and gaskets are unaffected by direct cntact with 18 / Octber 2017 / Indian Plumbing Tday

cncrete, care must be taken t prperly supprt any piping system when puring cncrete, s that the weight f the cncrete des nt affect the piping system.

becme imbedded int crevices, shields r clamps n cuplings. Suggested hangers INSTALLATION PROCEDURES & INSTRUCTIONS Abve Grund Installatin Hrizntal Piping - Suspended 1.

Jints used fr cnnecting hubless pipes pssess sufficient shear strength t require ne hanger per jint.

2 Meter develped length shall be supprted at alternate cuplings 3. Supprt hrizntal pipes and fittings sufficiently t maintain alignment and prevent sagging r grade reversal 4.

6 cncrete, care must be taken t prperly supprt any piping system when puring cncrete, s that the weight f the cncrete des nt affect the piping system. While nt required due t any crrsin issues, a gd practice t aid in any future maintenance r excavatin f a system wuld be t lsely wrap the hubless cuplings with plyethylene sheet, s that cncrete des nt becme imbedded int crevices, shields r clamps n cuplings. Suggested hangers INSTALLATION PROCEDURES & INSTRUCTIONS Abve Grund Installatin Hrizntal Piping - Suspended 1. Hubless pipe installed in hrizntal psitin shall be supprted at every cupling. The hanger shall be placed within 450mm f the cupling. Jints used fr cnnecting hubless pipes pssess sufficient shear strength t require ne hanger per jint. Fr DN 200mm and abve hubless pipes, hanger shall be placed n bth sides f the cupling when installing full 3000mm length. 2. Installatins requiring multiple jints within a 1.2 Meter develped length shall be supprted at alternate cuplings 3. Supprt hrizntal pipes and fittings sufficiently t maintain alignment and prevent sagging r grade reversal 4. Supprt terminal ends f all hrizntal runs / branches and each change f directin r alignment with an apprved hanger 5. P-Traps r clset bends installed shuld be firmly secured against mvement in any directin 6. Hrizntal pipes and fittings abve DN 100mm and larger shall be suitably braced t prevent hrizntal mvement. This shall be dne at every branch pening r change f directin by use f braces, blck r any ther suitable methd t prevent mvement 7. Adequate prvisin shuld be made t prevent shear where cmpnents are suspended mre than 450mm by means f nn rigid hangers, they shuld be suitably braced against hrizntal mvement which is called sway bracing Installed Trap Cl 'P' Trap CI Cast Irn Trap 20 / Octber 2017 / Indian Plumbing Tday

8. When the system is filled with water, sufficient beam strength is prvided by cast Irn pipe t carry the lad with hangers every 3000mm fllwing supprts r clamps may be used depending n cnditins.

7 8. When the system is filled with water, sufficient beam strength is prvided by cast Irn pipe t carry the lad with hangers every 3000mm fllwing supprts r clamps may be used depending n cnditins. Hangers may be fastened by expansin blts/screws/tggle blts etc. Vertical Piping: 1. Secure Vertical piping at sufficiently clse intervals t keep the pipe in alignment and t supprt its cntents. 2. Supprt stacks at their bases and at sufficient flr intervals. TESTING AND INSPECTION Once the installatin is cmpleted, it is imprtant t test and inspect all piping wrk fr leaks. Cncealed wrk shuld remain uncvered until the required tests are made and apprved at site. When testing, the system shuld be prperly restrained at all bends, changes f directin and the end f runs. There are varius types f test prcedures used fr testing installed hubless cast irn pipes and fittings, water r smke test is recmmended. Prper safety precautins, prcedures and prtective equipment shuld be used during all testing prcedures. It is suggested t cnsider the lcal cnditins, cdes, manufacturers & engineers instructins. WATER TEST A water r hydrstatic test is the mst cmmn test used t inspect a cmpleted cast irn sil pipe installatin. This is the recmmended test in mst plumbing cdes. The purpse f the test is t lcate any leaks at the jints and crrect these prir t the clsing in f the piping r backfilling f the undergrund piping. T islate each flr r sectin being tested, test plugs are inserted thrugh test tees in the stacks. All ther penings shuld be plugged r capped with test plugs r test caps. Prir t the beginning f the test, all bends, changes f directin and ends f runs shuld be prperly restrained. During the test, thrust frces are exerted at these lcatins. Thrust is equal t the hydrstatic pressure multiplied by area. Thrust pressure, if nt restrained, will result in jint mvement r separatin causing failure f the test. Prir t testing, cap r plug all penings in the lwer sectin f the sectin t be tested. Fill the system t be tested with water at the highest pint. As water fills a vertical cylinder r a vertical pipe it creates hydrstatic pressure. The pressure increases as the height f the water in the vertical pipe increases. 3000mm head f hydrstatic site test pressure (0.03 MPa) is recmmended. Filling the system slwly shuld allw any air in the system t escape as the water rises in the vertical pipe. All air entrapped in the system shuld be expelled prir t beginning f the test. Failure t remve entrapped air may give faulty test results. Once the stack is filled t 3000mm f head, a visual inspectin f the sectin being tested shuld be made t find any leaks. Where leaks are fund in a hubless system, in mst cases, hubless cuplings have nt been trqued. Prper trqueing will prbably crrect the prblem. Fifteen minutes is suitable time fr the water test. Once the system has been successfully tested it shuld be drained and the next sectin shuld be prepared fr testing. SMOKE TEST When a smke test is required by engineers, architects, r plumbing cdes, it is applied t all parts f the drainage and venting system after all fixtures have been permanently cnnected and all traps filled with water. A thick, penetrating smke prduced by ne r mre smke machines is intrduced int the system thrugh a suitable pening. As the smke appears at the stack pening n the rf, the pening is clsed ff and the intrductin f smke is cntinued until a pressure equal t ne inch f water is built up and maintained fr fifteen minutes withut the additin f mre smke. Under this pressure smke shuld nt be visible at any pint, cnnectin r fixture. All windws in the building shuld be clsed until the test is cmpleted. Indian Plumbing Tday / Octber 2017 / 21

PRECAUTIONS TO BE TAKEN DURING INSTALLATION OF HUBLESS PIPES & FITTINGS Edges f pipes and fittings shuld be straight and perpendicular Pipes t be cut by using cutting machine Any burrs n edges f pipe

8 PRECAUTIONS TO BE TAKEN DURING INSTALLATION OF HUBLESS PIPES & FITTINGS Edges f pipes and fittings shuld be straight and perpendicular Pipes t be cut by using cutting machine Any burrs n edges f pipe and fitting shuld be perfectly grunded befre jinting Ensure that the ends f pipe r fitting rest prperly n central ring f EPDM rubber gasket All nuts and blts f cuplings shuld be tightened simultaneusly keeping same gap between them Ensure that the jints are prperly supprted, bth in hrizntal and vertical lines Prper supprting clamps with rubber inlay t be used After fitting and testing f hubless pipes and fittings its alignment in vertical r in hrizntal shuld nt be disturbed Dn t allw anything t hang ver r supprt fr ther services n hubless pipes & fittings lines Fllw all safety measures as per lcal cnditins, requirements, cdes, manufacturers r engineers instructins accrdingly. ipt Mr. B. Praveen is General Manager (Marketing and Business Develpment) and wrking with M/s Jayaswal Nec Industries Ltd., Nagpur. He has mre than 25 years f experience in Building Drainage System. Mbile: b.praveen@necindia.cm 22 / Octber 2017 / Indian Plumbing Tday

[Note to Engineer: Choose one below. Confirm with your geotech if you need further compaction.]

[Note to Engineer: Choose one below. Confirm with your geotech if you need further compaction.] 2-06 SUBGRADE PREPARATION (******) 2-06.3 Cnstructin Requirements 2-6.3(1) Subgrade fr Surfacing This sectin is supplemented with the fllwing: The subgrade must be suitable, as determined by the Engineer,