UNPLASTICIZED PVC (UPVC) PIPES & FITTINGS FOR POTABLE WATER SUPPLY
1 Applicable codes:
1.1 The laying of Un-plasticized PVC pipes and fittings / specials shall comply with all
currently applicable statutes, regulations, standards and codes. In particular the
following standards, unless otherwise specified herein, shall be referred. In all cases,
the latest revision of the standards/codes shall be referred to. Other IS: Codes not
specifically mentioned here but pertaining to the use of Un-plasticized PVC pipes shall
be part of this Specification.
Table No.1.1
IS No Title
IS 4985: 2000 Specification for un-plasticized PVC pipes for potable
water supply
IS 7634(PT-3): 2003 Code of practice for plastics pipes selection, Handling,
Storage and installation for potable water Supply
IS 7834(PT I to VIII): 1987 Specification for injection moulded PVC socket fittings
with solvent cement joints for water supply
IS 14182:1994 Solvent cement for use with un-plasticized polyvinyl
Chloride Plastic pipes and fittings
1.2 Solvent cementing technique for jointing PVC pipe lengths is cheaper, more efficient
and far simpler. PVC pipes do not become pitted or tuberculated and are unaffected by
fungi and bacteria and are resistant to a wide range of chemicals. They are immune to
galvanic and electrolytic attack, a problem frequently encountered in metal pipes,
especially when buried in corrosive soils or near brackish waters.
1.2.1 PVC pipes have elastic properties and their resistance to deformation resulting from
earth movements is superior compared to conventional pipe materials specially AC.
Thermal conductivity of PVC is very low compared to metals. Consequently water
transported in these pipes remains at a more uniform temperature. These pipes
generally come in 6m length.
1.3 Rigid PVC pipes weigh only 1/5th of conventional steel pipes of comparable sizes.
PVC pipes are available in sizes of outer dia, 20, 25, 32, 50, 63, 75, 90, 110, 140,
160, 250, 290 and 315mm at working pressures of 2.5,4,6, 10 kg/cm² as per IS
4985-1988.
2 Classification of pipes
The pipes shall be classified by pressure ratings (working pressures) at 27 C as follows:
Class of pipe Working Pressure (PN)
2
Class 1 0.25 MPa (2.5 kg/cm )
2
Class 2 0.4 MPa (4.0 kg/cm )
2
Class 3 0.6 MPa (6.0 kg/cm )
2
Class 4 0.8 MPa (8.0 kg/cm )
2
Class 5 1.0 MPa (10.0 kg/cm )
2
Class 6 1.25 MPa (12.5 kg/cm )
Signature of the Contractor. 66 Superintending Engineer,
MB Circle, Khammam.
3 DIMENSIONS OF PVC PIPES
3.1 The mean outside diameter, outside diameter at any point and their tolerances shall be
as given in table 1.2.
3.2 Mean outside diameters
The permissible variation (dem _dn) between the mean outside diameter (dem)
and the nominal outside diameter (dn) of a pipe shall be positive in the form +x,
where x is less than or equal to the greater of the following two values:
a) 0.3 mm, and
b) 0.003 dn rounded off to the next higher 0.1 [Link] thickness
The wall thickness of plain pipe and the plain portion of socket ended pipe
shall be as given in table. 1.2.
4 Tolerance on wall thickness
4.1 For pipes of minimum wall thickness 6 mm or less, the permissible variation between
the minimum wall thickness (emin) and the wall thickness at any point (e), (e-emin)
shall be positive in the form of +y, where y= 0.1 emin + 0.2 mm
4.2 For pipes of minimum wall thickness greater than 6 mm, the permissible variation of
wall thickness shall again be positive in the form of +y, where y would be applied in two
parts.
4.3 The average wall thickness shall be determined by taking at least six measurements of
wall thickness round the pipe and including both the absolute maximum and the
absolute minimum values. The tolerance applied to this average wall thickness from
these measurements shall be within the range 0.1 emin + 0.2 mm (see table 1.2)
4.4 The maximum wall thickness at any point shall be within the range 0.15 emin. (see
table 1.2)
4.5 The results of these calculation for checking tolerance shall be rounded off to the next
higher 0.1 mm
Signature of the Contractor. 67 Superintending Engineer,
MB Circle, Khammam.
Table No. 1.2
(Refer Table No. 1 IS 4985-2000)
Nominal
outside
Mean outside Outside Diameter
Diameter Working Pressure, MPa
Diameter At any point
(Nominal
size)
Class3 (6kg/sqcm) Class 4 (8kg/sqcm) Class 5 (10kg/sqcm)
Min Max Min Max
0.60 0.80 1.00
Avg Min Max Avg Min Max Avg Min Max
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
90 90.0 90.3 88.9 91.1 3.7 3.1 3.7 4.6 4.0 4.6 5.7 5.0 5.7
110 110.0 110.4 108.6 111.4 4.3 3.7 4.3 5.6 4.9 5.6 7.0 6.1 7.1
125 125.0 125.4 123.5 126.5 5.0 4.3 5.0 6.4 5.6 6.4 7.8 6.9 8.0
140 140.0 140.5 138.3 141.7 5.5 4.8 5.5 7.2 6.3 7.3 8.7 7.7 8.9
160 160.0 160.5 158.0 162.0 6.3 5.4 6.2 8.2 7.2 8.3 9.9 8.8 10.2
180 180.0 180.6 177.8 182.2 7.0 6.1 7.1 9.0 8.0 9.2 11.1 9.9 11.4
200 200.0 200.6 197.6 202.4 7.7 6.8 7.9 10.0 8.9 10.3 12.3 11.0 12.7
5 Length of pipe
The effective length of pipes shall be 4, 5, or 6 meters. For plain ended pipes the
overall length shall be measured from end to end. For socketed pipe for solvent
cement jointing the effective length of pipe shall be determined by subtracting
from the overall length, the socket length.
6 Dimensions of sockets pipes:-
6.1 The sockets formed at the ends of the pipes shall be parallel to the axis of the pipe. The
minimum length of any socket shall be = 0.5 x nominal outside diameter of the pipe
+6 mm.
6.2 Sockets for solvent cement jointing these shall conform to dimensions given in Table
1.3.
Table No.1.3
All dimensions in millimeters (Refer
Table No. 3 IS 4985-2000)
Mean socket internal diameter at
Normal size DN Socket Length LS
Mid-point of socket Length, dM
Min Min Max
(1) (2) (3) (4)
90 51.0 90.1 90.3
110 61.0 110.1 110.4
125 68.5 125.1 125.4
140 76.0 140.2 140.5
160 86.0 160.2 160.5
180 96.0 180.2 180.5
200 106.0 200.3 200.6
Signature of the Contractor. 68 Superintending Engineer,
MB Circle, Khammam.
6.3 The minimum length of any socket shall be Ls = 0.5xdn+6mm
7 Pipe ends:-
The ends of the pipes meant for solvent cementing (both plain and bell ended) shall be cleanly
cut and shall be reasonably square to the axis of the pipe or may be chamfered at the plain.
8 Physical and chemical characteristics
8.1 Visual appearance
8.2 The internal and external surface of the pipe shall be smooth, clean and free from
grooving and other defects. Slight shallow longitudinal grooves or irregularities in the
pipe shall be permissible provided the wall thickness remains within the permissible
limits. Each pipe may also be marked with the standard mark of BIS certification.
8.3 Opacity:-
8.4 The wall of the plain pipe shall not transmit more than 0.2 percent of the visible light
falling on it when tested in accordance with IS: 12235 (Part-3)
8.5 Effect on water:-
8.6 The pipe shall not have any detrimental effect on the composition of water flowing
through them.
9 Marking
9.1 Each pipe shall be clearly and indelibly marked in ink/paint or hot embossed on white
base at intervals of not more than 3 meters, in colour. The marking shall show the
following:
a) mark
b) Out side diameter,
c) Class of pipe and pressure rating,
d) Batch or lot number, and
e) The word plumbing in the case of plumbing pipes.
9.2 The information according to 9.1 shall be marked in colours as mentioned below:-
Working
Classof Colour of
pressure
Pipe Marking
Kg/sqcm
Class 2 4 Blue
Class 3 6 Green
Class 4 8 Brown
Yellow
Class 5 10
Signature of the Contractor. 69 Superintending Engineer,
MB Circle, Khammam.
9.3 In case of hot embossing, pipe shall also be provided near the end with circumferential
colour band to identify the class of pipe.
10 Handling and storage
10.1 Because of their lightweight, there may be a tendency for the PVC pipes to be thrown
much more than their metal counterparts. This should be discouraged and reasonable
care should be taken in handling and storage to prevent damage to the pipes.
10.2 On no account should pipes be dragged along the ground. Pipes should be given
adequate support at all times.
10.3 These pipes should not be stacked in large piles, specially under warm temperature
conditions, as the bottom pipes may be distorted thus giving rise to difficulty in pipe
alignment and jointing. For temporary storage in the field, where racks are not
provided, care should be taken that the ground is level, and free from loose stones.
Pipes stored thus should not exceed three layers and should be so stacked as to
prevent movement. It is also recommended not to store one pipe inside another. It is
advisable to follow the practices mentioned as per IS: 7634-Part-I.
10.4 PVC solvent cement should be stored in a cool place except when actually in use at the
site. The solvent cement has a limited self life when not stored in hermetically sealed
containers.
10.5 In rocky area 15 cm. cushion of sand or murum below and above the pipes should be
provided as per IS 7634 (Part III) : 2003.
11 Testing of Pipes
11.1 Reversion Test:
When tested by the immersion method prescribed in IS 12235 (Part 5), a length of pipe 200 + 20 mm long
shall not alter in length by more than 5 percent. In the case of socket end pipes, this test shall be carried
out on the plain portion of the pipe taken at least 100 mm away from the root of the socket.
11.2 Vicat Softening Temperature:
11.3 When tested by the method prescribed in IS 6307, the Vicat softening temperature of
the specimen shall not be less than 800C.
11.4 Sulphated Ash Content Test:
11.5 When tested the sulphated ash content in the pipe shall not exceed 11 percent.
11.6 Hydrostatic Characteristics:
When subjected to internal hydrostatic pressure test in accordance with the
procedure given in IS 12235 (Part 8), the pipe shall not fail during the
prescribed test duration. The temperatures and duration of the test shall
conform to the requirements given as per Table 1.4. The test shall be carried
out not earlier than 24 h after the pipes have been manufactured.
Signature of the Contractor. 70 Superintending Engineer,
MB Circle, Khammam.
Table No. 1.4
(Refer Table No. 6 IS 4985-2000) Requirements of
Pipes for Internal Hydrostatic Pressure Test
Test Test Test Duration Test Pressure
Temperature (Min. Holding Time) (Min.) MPa
0
(Min.) C h
1 2 3 4
Type test 60 1000 1.16 x PN (MPa)
Acceptance test 27 1 4.19 x PN (MPa)
12 Fittings:-
12.1 Size of Fittings
The sizes of the fittings shall be designated by the diameters of their
sockets. The inside diameters of the sockets of the fittings shall correspond
to the outside diameters of the pipes given in IS: 4985-1988. The general
requirement of the PVC socket fittings shall conform to IS: 7834 (part-1)
1987.
12.2 Minimum thickness:-Thickness at any place in a fitting shall not be less than 3 mm.
12.3 Socket length and diameter at Mid-point of socket Length
The minimum socket length of any fittings shall be as given by the expression
L= 0.5 D + 6 mm with a minimum of 12 mm.
Where:-
L= socket length, and
D= nominal inside diameter of fittings (corresponding to the outside
diameter of the pipe)
12.3.1. The socket length is applicable to socket fittings for pipes of any
diameter under pressure. The minimum socket lengths based on the
formula in 6.1 for socket.
12.3.2 The maximum and minimum dimensions of mean inside diameter at mid-point
of socket depth shall comply with those given in table 1.4.
Signature of the Contractor. 71 Superintending Engineer,
MB Circle, Khammam.
Table No. 1.4
Socket dimensions
All dimensions in millimeters. (Refer
Table No. 1 IS 7834 (part-1) -1987)
Minimum Socket Mean socket internal diameter at
Nominal Size
Length Mid-Point of socket Length
Minimum Maximum
(1) (2) (3) (4)
90 51 90.1 90.3
110 61 110.1 110.4
125 69 125.1 125.4
140 76 140.1 140.5
160 86 160.2 160.5
180 96 180.2 180.5
200 106 200.3 200.6
12.4 Marking for fittings
All fittings shall be clearly and indelibly marked at a prominent place visible even after the
installation of the fittings with the following:
a)
b) Size of the fitting and the appropriate class (working pressure) of IS:
4985-2000 to which the pressure rating of the fitting corresponds.
12.4.1 PVC fittings also conforming to specific requirements as prescribed in the relevant parts of
the standard may also be marked with the standard Mark.
12.4.2 Specific requirements for various PVC socket fittings with solvent cement jointsfor water
supplies shall be as mentioned below:
Table No.1.5
[Link] Type of fittings Relevant IS code
1. 45º Elbows IS: 7834 (Part-2)-1987
2. 90º Elbows IS: 7834 (Part-3)-1987
3. 90º Tees IS: 7834 (Part-4)-1987
4. 45º Tees IS: 7834 (Part-5)-1987
5. Sockets IS: 7834 (Part-6)-1987
6. Unions IS: 7834 (Part-7)-1987
7. Caps IS: 7834 (Part-8)-1987
13 Solvent cement jointing
13.1 PVC solvent cement is quick drying, therefore it shall be applied as quickly
and carefully as possibly and in consistence with good workmanship. For
larger sizes, it is advisable for two workers to work simultaneously on the
pipe and socket.
13.2 Solvent cement shall conform to IS:14182.
Signature of the Contractor. 72 Superintending Engineer,
MB Circle, Khammam.
13.3 Dip the applicator brush in the solvent cement and apply a liberal coat of
cement to the end of the pipe up to the insertion depth.
13.4 Apply a uniform thin coat of solvent cement inside the socket, working
axially from the inside of the socket to the outside. Do not apply any
cement on the shoulders of the socket (socket-to-pipe transition area). Care
should be taken not to apply excess cement inside the socket. Excess
cement in the socket will be pushed further into the pipe during assembly
and cause the pipe to soften and weaken at that point. Hot and dry climates
generally require slightly thicker coatings of solvent cement.
13.5 In climates with large differences between day and night temperatures, it
is advisable to make joints early in the morning or in the evening when it is
cooler. Thus, the joints are prevented from being pulled apart if the pipes
contract.
13.6 For pipe installation solvent glued spigot is inserted in the socket up to
the shoulder and then after a quarter (90º) turn is given to evenly
distribute the cement over the treated surface.
13.6.1 Within 20 second after the last application of solvent cement, insert the pipe in to
socket in a single steady and every controlled but forceful action. Press it in fully
until it bottoms. No. hammer blows should be used. If there is any sign of drying of
the cement coat before insertion; the surface should be re-coated, avoiding
application of excess cement in the socket. Once the insertion is completed,
hold in place for 1 min without shifting the pipe in the socket.
13.7 Immediately after assembly, wipe the excess solvent cement from
the pipe at the end of the socket. A properly made joint will have a
uniform bead around its entire perimeter. Any gaps in this bead may
be indicative of an improper joint due to insufficient cement or the use
of a lighter-bodied cement than the one recommended.
Signature of the Contractor. 73 Superintending Engineer,
MB Circle, Khammam.
14 Trench:-
14.1 Location: Drinking water pipelines should not be located below sewerage
pipelines. Where a pipeline runs parallel to other pipelines or cables, the
distance between them should not be less than 0.4 m.
14.2 At points of congestion, a distance of 0.2 m should be maintained unless
steps are taken to prevent direct contact.
14.3 Width: Trenches should be of adequate width to allow the burial of pipe, while
being as narrow as practical. If expansion and contraction are not problems
and snaking of pipe is not required, minimum trench widths may be
obtained by jointing the pipe outside the trench and then lowering the piping
into the trench after the testing. A trench width of two or three times the pipe
diameter is a good rule of thumb. Narrow (unsupported) trench width and
supported trench width shall be as given under:
Table No.1.6
Unsupported Narrow Supported Trench Width,
Trench Width (Minimum) (Minimum)
Nominal pipe size Number of Number of pipe Width
(Diameter in mm) pipe Diameter Width (mm) Diameter (mm)
90 5.0 450 10.0 900
110 4.0 450 8.2 900
125 4.0 500 7.2 900
140 3.9 550 6.4 900
160 3.5 560 5.6 900
180 3.2 580 5.0 900
200 3.0 600 4.5 900
14.4 Where necessary to prevent cave-ins, trench excavations in unstable soil shall be
adequately supported. As backfill is placed and sheeting withdrawn, the void left by the
withdrawn sheeting shall be filled and compacted before withdrawing the next increment.
14.5 Trench Bottom
The trench bottom shall be constructed to provide a firm, stable and uniform support for
the full length of the pipeline. There should be no sharp objects that may cause point
loading.
Any large rocks, hard pan, or stones larger than 20 mm should be removed to permit a
minimum bedding thickness of 100-150 mm under the pipe.
For pipes of diameters 100 mm or greater, bell holes in the bedding, under each socket
joint, shall be provided by removing some of the bedding material, to accommodate the
larger diameter of the joint and to permit the joint to be made properly.
Signature of the Contractor. 74 Superintending Engineer,
MB Circle, Khammam.
14.5.1 Excavated material should be deposited at a sufficient distance from the trench so
that damage is not caused to the pipe line through falling stones/debris.
14.5.2 Prepare the bedding by laying on soft soil and alternatively compacting and
watering sparingly until an effective thickness of 100 to 150 mm is achieved.
15 Laying
15.1 Lay the pipe in the trench after ensuring that bell holes have been provided for at
the appropriate places in the bedding (Pipes of diameter 110 mm or less, with no
live load application, do not require bell holes in the trench bottom).
15.2 These have to be refilled carefully after testing of the pipeline and prior to complete
backfilling of the trench.
15.3 Though not essential, the pipes should be laid with the spigots entered into the
sockets in the same directions as the intended flow of water.
16 Minimum cover
16.1 A minimum cover of 0.9 m required when truck traffic is expected.
16.2 A minimum cover of 1.8m over pipe when heavy truck or locomotive traffic (dynamic
loads) is expected. Usually pipe below 2.0 m of cover are not affected significantly
by dynamic loads. If the application prevents deep burial of the pipe and heavy
traffic passing over the pipe is expected, it would be advisable to use steel or
reinforced concrete casing to prevent damage to the pipe.
17 Anchoring
17.1 The purpose of the anchor block is to transfer the total thrust to the trench sides. It is
therefore important to take account of the load-bearing capacity of the surrounding
ground.
17.2 Recommended mixture for concrete is one part cement, two parts washed sand and
two parts gravel.
17.3 Where concrete would be in direct contact with the pipe or fittings, these should be
wrapped with a compressible material, for example rubber sheet or foamed
polyethylene sheet, to accommodate creep and prevent the occurrence of high local
stress concentrations.
Signature of the Contractor. 75 Superintending Engineer,
MB Circle, Khammam.
18 Back-filling
18.1 The first side fill or hunching layer should be placed by hand and compacted in
layers under the lower quadrants of the pipe up to the spring level (half the vertical
diameter) of the pipe.
18.2 Compaction can be done by careful trampling with the feet or with trampling tool.
18.3 Care should be taken to leave adequate area around the joint free of backfill to
allow for inspection during testing of the pipeline.
18.4 Successive layers of backfill of 75 mm thickness may then be placed over and
compacted to a height above the crown of not less than 150 mm. Light vibrating
machinery may be used, but not directly above the pipe.
18.5 On completion of the surround to the pipe, suitable excavated material may be then
replaced as backfill in 250 mm compacted layers up to the top of the trench.
18.6 No heavy compaction equipment to be employed until there is at least 300mm of fill
above the crown of the pipe.
19 Measurement
19.1 The net length of pipes as laid or installed shall be measured in running meters
correct to a cm. Specials shall be excluded and enumerated and paid separately
under the relevant item. The portion of pipe at the joints (inside the joint) shall not be
included in the length of the pipe work. Masonry and concrete work (as required)
shall be measured and paid for separately under relevant item of work.
20 Rates:
The rate shall include the cost of the material and labour charges involved in the
operation prescribed item of work.
Signature of the Contractor. 76 Superintending Engineer,
MB Circle, Khammam.
